Laminates for absorbent articles

ABSTRACT

Three-dimensional laminates and methods for making the same are provided. The three-dimensional laminates may be apertured and may have welds between various substrates. The three-dimensional laminates may be used in absorbent articles, such as diapers and pants, for example, as topsheets, as topsheets and acquisition layers, or as outer cover materials, for example. The three-dimensional laminates may be produced on an absorbent article manufacturing line.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit, under 35 U.S.C. § 119(e), to U.S.Provisional Patent Application No. 62/458,051, filed on Feb. 13, 2017;U.S. Provisional Patent Application No. 62/574,237, filed on Oct. 19,2017; U.S. Provisional Patent Application No. 62/458,060, filed on Feb.13, 2017; U.S. Provisional Patent Application No. 62/574,240, filed onOct. 19, 2017; U.S. Provisional Patent Application No. 62/458,173, filedon Feb. 13, 2017; U.S. Provisional Patent Application No. 62/574,242,filed on Oct. 19, 2017; and U.S. Provisional Patent Application No.62/574,245, filed on Oct. 19, 2017, which are all herein incorporated byreference in their entirety.

FIELD

The present disclosure is generally directed to laminates for absorbentarticles and methods of making the same. The laminates may comprise atleast one three-dimensional substrate.

BACKGROUND

Three-dimensional substrates have a variety of uses in variousindustries. One of the industries that has interest in three-dimensionalsubstrates is the absorbent article industry. The absorbent articleindustry manufactures products such as diapers, pants, sanitary napkins,tampons, and adult incontinence pants, diapers, and products, forexample. These absorbent articles may desirably comprise one or morethree-dimensional substrates or laminates with at least onethree-dimensional substrate as portions of or as topsheets, acquisitionlayers, distribution layers, outer cover materials, and/or othercomponents, for example. Three-dimensional means materials that havethree-dimensional elements more than a standard generally planarmaterial. As an example, three-dimensional elements may extend 0.5 mm to5 mm, 1 mm to 5 mm, or 2 mm to 5 mm, for example, from a planar surfaceof the substrates. Three-dimensional substrates used in absorbentarticles are typically manufactured at a first location and then shippedto a second, different location for incorporation into absorbentarticles. The first location is typically a three-dimensional substratemanufacturer, or a nonwoven or film manufacturer, and the second,different location is typically an absorbent article manufacturer. Afirst issue that arises in these situations is the three-dimensionalsubstrates or laminates need to be tightly wound at the first locationand then shipped to a second, different location. This typically reducesthe three-dimensionality of the substrates or laminates due to theirlack of ability to withstand compression and tensioning caused by thewinding. A second issue that arises in these situations is thesubstrates or laminates need to be unwound and fed into absorbentarticle manufacturing lines at the second, different location. Thistypically further reduces the three-dimensionality of the substrates orlaminates owing to their lack of ability to withstand compression andtensioning caused by the unwinding. Finally, compact packaging, as oftenused for absorbent articles, reduces three-dimensionality further. Whatis needed are reliable methods and tooling for producingthree-dimensional substrates or laminate comprising one or morethree-dimensional substrates on an absorbent article manufacturing linethat reduce three-dimensional element compression and distortion.

Additionally, when three-dimensional substrates (e.g., absorbent articletopsheets) are joined to an additional substrate, to form a laminate,sometimes delamination occurs. The additional substrate may bethree-dimensional or planar. Delamination is quite undesirable in thatit reflects poorly on product quality with consumers. Improved methodsof joining two substrates together are needed to avoid, or at leastreduce, delamination concerns during use of the laminates.

SUMMARY

The present disclosure provides methods and tooling for producingthree-dimensional substrates or laminates comprising a three-dimensionalsubstrate on an absorbent article manufacturing line. By creating thethree-dimensional substrates or laminates on the absorbent articlemanufacturing line, winding, unwinding, and shipping may be eliminated.Further, the methods and tooling of the present disclosure may providethe three-dimensional substrates or laminate the ability to at leastreduce three-dimensional element compression, even during compressionpackaging of the absorbent articles. This compression resistance may beaccomplished by providing compressed regions or densified areas in atleast some of the three-dimensional elements of the three-dimensionalsubstrates or laminates. The compressed regions or densified areas maybe formed around aperture perimeters, or portions of apertureperimeters, to stabilize the apertures at line speed.

The present disclosure also provides methods and laminates that reducedelamination between two or more substrates, with at least one of thesubstrates being a three-dimensional substrate. As one example, thepresent disclosure provides methods and laminates for reducingdelamination between a three-dimensional substrate joined to a planarsubstrate. As another example, the present disclosure provides methodsand laminates for reducing delamination between two or more stackedthree-dimensional substrates. The first substrate may be centered on thesecond substrate (or may have the same dimensions as the secondsubstrate). The first substrate and the second substrate may then besubjected to a three-dimensional element and/or aperturing process tojoin the two substrates. In either case, the joining of the substratesmay be improved by an additional step of applying welds between thesubstrates. One example of a weld is thermo-mechanical weld, such as aheat/pressure bond or an ultrasonic weld. Ultrasonic welds may be formedusing heat and a light amount of pressure. Heat/pressure bonds may beformed using a large amount of pressure, generating heat or by the useof a large amount of pressure and heat. These welds may aid in reducingdelamination between various substrates in the laminates and, thereby,increasing the consumer experience and promoting consumer views ofhigher product quality.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter which is regarded as formingthe present invention, it is believed that the present disclosure willbe better understood from the following description which is taken inconjunction with the accompanying drawings in which the designations areused to designate substantially identical elements and in which:

FIG. 1 is a view of a pair of rolls having a substrate conveyedtherebetween;

FIG. 2 is a top view of an example portion of a first roll of the pairof rolls of FIG. 1;

FIG. 2A is a cross-sectional view of the first roll taken about line2A-2A of FIG. 2;

FIG. 3 is a top view of an example portion of a second roll of the pairof rolls of FIG. 1;

FIG. 3A is a cross-sectional view of the second roll taken about line3A-3A of FIG. 3;

FIG. 4 is a simplified schematic cross-sectional illustration of theportion of the first roll of FIG. 2A intermeshed with the portion of thesecond roll of FIG. 3A;

FIG. 4A is an exploded view of region 4A in FIG. 4;

FIG. 5 is a cross-sectional view of a portion of an example projectionof the second roll;

FIG. 6 is another cross-sectional view of a portion of an exampleprojection of the second roll;

FIGS. 7A-7G are example top views of portions of distal ends ofprojections of the second roll;

FIGS. 8A-8F are example top views of portions of projections of thefirst roll;

FIG. 9 is a cross-sectional view of a portion of a first roll and aportion of a second roll intermeshed with each other;

FIG. 9A is a cross-sectional blown up view of detail 9A of FIG. 9;

FIG. 10 is a top view of an example precursor substrate that may beconveyed through a nip formed between first and second rolls of thepresent disclosure;

FIG. 11 is a cross-sectional view of the precursor substrate taken aboutline 11-11 of FIG. 10;

FIG. 12 is a cross-sectional view of the precursor substrate taken aboutline 12-12 of FIG. 10;

FIG. 13 is a top view of an example substrate after being conveyedthrough the nip and having a central longitudinal strip comprisingthree-dimensional elements and apertures;

FIG. 14 illustrates first and second rolls that may create a substratehaving a central longitudinal strip as illustrated in FIG. 13;

FIG. 15 is a perspective view of two stretching rolls for stretchingside portions of the substrate of FIG. 13;

FIG. 16 is a cross-sectional illustration of ridges and grooves in eachof the rolls of FIG. 15;

FIG. 17 is a schematic illustration of a three roll process of creatinga substrate having a first substrate with three-dimensional elements andapertures and a second generally planar substrate with only apertures;

FIG. 18 is a cross-sectional view taken about detail 18 of FIG. 17;

FIG. 19 is a top perspective view of an example three-dimensionalapertured substrate produced by the first and second rolls 8, 10 of FIG.1;

FIG. 20 is a top view of an example three-dimensional, aperturedsubstrate produced by the first and second rolls 8, 10 of FIG. 1;

FIG. 21 is a back view of the example three-dimensional, aperturedsubstrate of FIG. 20;

FIG. 22 is a cross-sectional view taken through the examplethree-dimensional, apertured substrate of FIG. 20;

FIG. 23 is a simplified schematic cross-sectional example illustrationof the rolls 8, 10 that are configured primarily for creatingthree-dimensional elements and compressed regions in the precursorsubstrate 4 and not apertures; and

FIG. 24 is a simplified schematic cross-sectional example illustrationof the rolls 8, 10 that are configured primarily for creating aperturesand compressed regions in the precursor substrate 4 and notthree-dimensional elements or more limited (e.g., less height) threedimensional features compared to the rolls 8, 10 of FIG. 4.

FIG. 25 is a simplified schematic cross-sectional example illustrationof the rolls 8, 10 that are configured primarily for creatingthree-dimensional elements and compressed regions in the precursorsubstrate 4 and not apertures;

FIG. 26 is a simplified schematic cross-sectional example illustrationof the rolls 8, 10 that are configured primarily for creating aperturesand compressed regions in the precursor substrate 4 and notthree-dimensional elements or more limited (e.g., less height) threedimensional features compared to the rolls 8, 10 of FIG. 4 and FIG. 24;

FIG. 27 is a simplified schematic cross-sectional example illustrationof the rolls 8, 10 that are configured for creating apertures andthree-dimensional elements in the precursor substrate 4, but notcompressed regions; and

FIG. 28 is a simplified schematic cross-sectional illustration of aportion of a first roll of intermeshed with a portion of a second roll;

FIG. 28A is an exploded view of region 28A in FIG. 28;

FIG. 29 is a top view microscope photograph of a portion of athree-dimensional, aperture, two substrate laminate having welds;

FIGS. 30-32 are example schematic cross-sectional side views of welds ina two substrate laminate;

FIG. 33 is a schematic illustration of one way welds may be applied to atwo substrate laminate;

FIGS. 34A-34D illustrate three-dimensional, apertured, laminates withvarious weld patterns;

FIG. 35 is a schematic illustration of a three-roll configuration forproducing a three-dimensional laminate with welds;

FIG. 35A is a detail view of section 35A of FIG. 35;

FIG. 35B is a detail view of section 35B of FIG. 35;

FIG. 36 is a schematic illustration of a four-roll configuration forproducing a three-dimensional laminate with welds;

FIG. 37 is a schematic illustration of a three-roll configuration forproducing a three-dimensional laminate with welds, wherein the laminatehas one generally planar substrate;

FIG. 37A is a detail view of section 37A of FIG. 37;

FIG. 37B is a detail view of section 37B of FIG. 37;

FIG. 38 is a schematic illustration of a four-roll configuration forproducing a three-dimensional laminate with welds, wherein the laminatehas one generally planar substrate;

FIG. 38A is a schematic illustration of a two roll configuration forproducing a three-dimensional laminate having three-dimensionalelements, apertures, and welds;

FIG. 38B is a detail view of section 38B of FIG. 38A;

FIG. 38C is a schematic illustration of a roll configuration forproducing a three-dimensional laminate having three-dimensionalelements, apertures, and welds;

FIG. 39 is a plan view of an example absorbent article in the form of ataped diaper, garment-facing surface facing the viewer, in a flatlaid-out state;

FIG. 40 is a plan view of the example absorbent article of FIG. 39,wearer-facing surface facing the viewer, in a flat laid-out state;

FIG. 41 is a front perspective view of the absorbent article of FIGS. 39and 40 in a fastened position;

FIG. 42 is a front perspective view of an absorbent article in the formof a pant;

FIG. 43 is a rear perspective view of the absorbent article of FIG. 42;

FIG. 44 is a plan view of the absorbent article of FIG. 42, laid flat,with a garment-facing surface facing the viewer;

FIG. 45 is a cross-sectional view of the absorbent article taken aboutline 45-45 of FIG. 44;

FIG. 46 is an alternative cross-sectional view of the absorbent articletaken about line 46-46 of FIG. 44;

FIG. 47 is a plan view of an example absorbent core or an absorbentarticle;

FIG. 48 is a cross-sectional view, taken about line 48-48, of theabsorbent core of FIG. 47;

FIG. 49 is a cross-sectional view, taken about line 49-49, of theabsorbent core of FIG. 47;

FIG. 50 is a plan view of an example absorbent article of the presentdisclosure that is a sanitary napkin;

FIG. 51 is an example cross-sectional view taken within a front waistregion of an absorbent article;

FIG. 52 is an example cross-sectional view taken within a crotch regionof an absorbent article;

FIG. 53 is an example cross-sectional view taken within a back waistregion of an absorbent article;

FIG. 54 is a package of absorbent articles of the present disclosure,with portions of the package cut-away to show the articles;

FIG. 55 is a top view of a portion of an example first roll 8;

FIG. 55A is a cross-sectional view of a portion of the first roll 8taken about line 55A-55A of FIG. 55;

FIG. 56 is a top view of a portion of an example second roll 10;

FIG. 56A is a cross-sectional view of a portion of the second roll 10taken about line 56A-56A of FIG. 56;

FIG. 57 is an example of a wrapping configuration for the substrate orsubstrates passing through the various first and second rolls of thepresent disclosure; and

FIG. 58 is another example of a wrapping configuration for the substrateor substrates passing through various the first and second rolls of thepresent disclosure.

DETAILED DESCRIPTION

Various non-limiting forms of the present disclosure will now bedescribed to provide an overall understanding of the principles of thestructure, function, manufacture, and use of the laminates for absorbentarticles and methods of making the same disclosed herein. One or moreexamples of these non-limiting forms are illustrated in the accompanyingdrawings. Those of ordinary skill in the art will understand that thelaminates for absorbent articles and methods of making the samespecifically described herein and illustrated in the accompanyingdrawings are non-limiting example forms and that the scope of thevarious non-limiting forms of the present disclosure are defined solelyby the claims. The features illustrated or described in connection withone non-limiting form may be combined with the features of othernon-limiting forms. Such modifications and variations are intended to beincluded within the scope of the present disclosure.

Initially, the process of making three-dimensional substrates on anabsorbent article manufacturing line will be discussed, followed by adiscussion of welding, bonding, or otherwise joining the substratestogether to form laminates that resist delamination, and some of whichresist three-dimensional element compression.

The present disclosure is directed, in part, to methods and tooling formaking three-dimensional substrates on an absorbent articlemanufacturing line. The three-dimensional substrates may be apertured.Referring to FIG. 1, the three-dimensional substrates, orthree-dimensional apertured substrates 2, may be created by conveying aprecursor substrate 4 through a nip 6 formed between a first roll 8 anda second roll 10. At least portions of the first roll 8 may beintermeshing engaged with at least portions of the second roll 10.Portions of the first and second rolls that are not in intermeshingcontact may be in rolling contact or not in contact at all. Details ofthe first and second rolls 8, 10 will be illustrated in later figures.The precursor substrate 4, the first roll 8, the second roll 10, and/orthe three-dimensional substrate or three-dimensional apertured formedsubstrate 2 may be heated to promote better retention ofthree-dimensional elements in the formed substrate 2 and allow easierformation of three-dimensional elements and apertures.

The precursor substrate 4 may have a thermoplastic component (e.g., oneor more films and/or one or more nonwoven materials). The precursorsubstrate 4 may have any suitable number of substrates, such as one,two, or three, for example. Any or all of the substrates may compriseone or more nonwoven materials (or nonwoven fibers), films, coformmaterials, cellulosic materials (or cellulosic fibers), cotton materials(or cotton fibers), natural materials (or natural fibers), orcombinations thereof. As an example, a precursor substrate may have twoor more substrates of nonwoven materials, one or more substrates offilms and one or more substrates of nonwoven materials, and/or two ormore substrates of films. The various substrates may have the same size,shape, density, basis weight, and composition or may have differentsizes, shapes, densities, basis weights, and compositions as will bediscussed in further detail below.

Referring again to FIG. 1, the first and second roll 8 and 10 may beconfigured to create only three-dimensional elements in the precursorsubstrate 4 or may be configured to create three-dimensional elementsand apertures in the precursor substrate 4 to form a three-dimensional,apertured formed substrate 2. The first roll 8 may rotate about a firstrotational axis 12 in the direction indicated by the arrow on the firstroll 8 and the second roll 10 may rotate about a second rotational axis14 in the direction indicated by the arrow on the second roll 10. Inother instances, the first roll 8 may rotate in the opposition directionas the arrow on the first roll 8 and the second roll 10 may rotate inthe opposite direction as the arrow on the second roll 10, for example.The first roll 8 may comprise a first radial outer surface 16 and thesecond roll 10 may comprise a second radial outer surface 18. The firstrotational axis 12 and the second rotational axis 14 may be positionedgenerally parallel to each other to form a nip 6 between the first andsecond rolls 8, 10. The precursor substrate 4 may be conveyed in amachine direction (arrow MD) on an absorbent article manufacturing linethrough the nip 6.

FIG. 2 is a front view of a portion of an example of the first roll 8.FIG. 2A is a cross-sectional view of FIG. 2 taken about line 2A-2A. Thefirst roll 8 may comprise a first plurality of projections 20 extendingat least partially outwardly from the first radial outer surface 16. Thefirst plurality of projections 20 may be configured to form, or at leastpartially form apertures in the precursor substrate 4. In someinstances, distal ends of the projections 20 may be rounded to merelyform three-dimensional elements in the precursor substrate 4 instead ofapertures. The first roll 8 may also comprise a first plurality ofrecesses 22 defined in the first radial outer surface 16. At least someof, most of, or all of the first plurality of projections 20 maycomprise first distal portions 24 comprising elongated aperturingstructures. First distal ends 26 of the first distal portions 24 mayform a point. The term “point” as used herein may be at least partiallyrounded off, but still capable of puncturing a precursor substrate. Theterm “point” also includes a configuration where pins extend from thedistal ends, wherein the pins create the apertures. The first distalportions 24 may comprise one or more side walls 28. At least some of,most of, or all of the first plurality of projections 20 may eachcomprise a first base 30. The first plurality of projections 20 maycomprise a central longitudinal axis 32 that intersects the point orfirst distal end 26. The base 30 may comprise side walls 34 that mayextend parallel to, or substantially parallel to, the first centrallongitudinal axis 32. In other instances, the side walls 34 may extendwithin +/−25 degrees of the first central longitudinal axis 32. The sidewalls 34, in some instances, may also be arcuate or have arcuateportions.

Still referring to FIGS. 2 and 2A, the first distal portions 24 may formcones or conical structures. In such instances, the first distalportions 24 may have a single side wall 28 that surrounds the firstcentral longitudinal axis 32. In other instances, the first distalportions 24 may form other polygonal shapes where two or more side walls28 are formed. As an example, the first distal portions 24 may formtetrahedron structures with three separate side walls. In eitherinstance, the side wall or side walls 28 may not be fully continuousaround the first central longitudinal axis 32 as will be explained infurther detail below. The side wall or walls 28, whether continuous ordiscontinuous, may have a first angle in the range of about 5 degrees toabout 50 degrees, about 10 degrees to about 30 degrees, about 15 degreesto about 25 degrees, about 18 degrees, about 20 degrees to about 80degrees, about 30 degrees to about 70 degrees, about 35 degrees to about65 degrees, about 40 degrees to about 60 degrees, about 40 degrees toabout 55 degrees, or about 40 degrees to about 50 degrees, relative tothe first central longitudinal axis 32, specially reciting all 0.1degree increments within the specified ranges and all ranges formedtherein or thereby. Referring to FIG. 2, at least some of theprojections of first plurality of projections 20 may be surrounded byfour recesses of the first plurality of recesses 22, for example. Againreferring to FIG. 2, at least some of the recesses of the firstplurality of recesses 22 may be surrounded by four projections of thefirst plurality of projections 20, for example.

Referring to FIG. 2A, at least some of, or all of, the bases 30 of thefirst plurality of projections 20 may have a first width, W1, taken in adirection generally parallel to the first rotational axis 12 (orperpendicular to the first central longitudinal axis 32). At least someof the recesses 22 in areas adjacent to the bases 30 may have a secondwidth, W2, taken in a direction generally parallel to the firstrotational axis 12. The first width, W1, may be the same as, differentthan, smaller than, or greater than the second width, W2.

FIG. 3 is a front view of a portion of an example of the second roll 10.FIG. 3A is a cross-sectional view of FIG. 3 taken about line 3A-3A. Thesecond roll 10 may comprise a second plurality of projections 36extending at least partially outwardly from the second radial outersurface 18. The second plurality of projections 36 are configured toform three-dimensional elements in the precursor substrate 4. The secondplurality of projections 36 have a second plurality of recesses 38defined in the second radial outer surface 18. At least some of, mostof, or all of the second plurality of projections 36 comprise seconddistal portions 40 and second distal ends 42. The second plurality ofprojections 36 comprise bases 44. At least some of, most of, or all ofthe second plurality of projections 36 each comprise shoulders 46positioned intermediate the bases 44 and the second distal ends 42. Thesecond plurality of projections 36 each comprise a central longitudinalaxis 48 extending in a direction generally perpendicular to the secondrotation axis 14. The shoulders 46 may have a second angle relative tothe second central longitudinal axis 48 in the range of about 2 degreesto about 40 degrees, about 3 degrees to about 30 degrees, about 5degrees to about 20 degrees, about 3 degrees to about 15 degrees, about10 degrees, about 20 degrees to about 80 degrees, about 30 degrees toabout 70 degrees, about 35 degrees to about 65 degrees, about 40 degreesto about 60 degrees, about 40 degrees to about 55 degrees, or about 40degrees to about 50 degrees, relative to the second central longitudinalaxis 48, specially reciting all 0.1 degree increments within thespecified ranges and all ranges formed therein or thereby. The firstangle of the first distal portions 24 may be the same as or differentthan the second angle of the shoulders 46. As an example, the firstangle may be within about +/−0.01 degrees to about 15 degrees, or withinabout +/−0.01 degrees to about 10 degrees, of the second angle,specifically including all. 0.001 degree increments within the specifiedranges and all ranges formed therein or thereby. As further examples,the first angle may be with +/−15, 14, 13, 12, 11, 10, 9, 8, 6, 5, 4, 3,2, 1.5, 1, 0.75, 0.5, 0.25, or 0.1 degrees of the second angle. As yetanother example the first angle may be substantially the same as (e.g.,+/−0.5 degrees) or the same as the second angle. The purpose of havingthe first and second angles the same, substantially the same, orrelatively close to each other is to create a compressed region ordensified area at least partially, or fully, surrounding a portion ofthree-dimensional elements (or surrounding or partially surrounding theapertures) in the precursor substrate 4. These compressed regions ordensified areas help resist compression (such as from packaging) andhelp maintain the three-dimensional elements. The compressed regions maybe formed on portions of the three-dimensional elements and/or may atleast partially surround perimeters of the apertures to stabilize thethree-dimensional elements and/or the apertures when made at line speed.The compressed regions or densified areas are not merely primary fiberbonds used in the formation of a nonwoven substrate (i.e., bonds used tohold the fibers together).

Referring to FIG. 3, at least some of the projections of secondplurality of projections 36 may be surrounded by four recesses of thesecond plurality of recesses 38. Again referring to FIG. 3, at leastsome of the recesses of the second plurality of recesses 38 may besurrounded by four projections of the second plurality of projections36.

Referring to FIG. 3A, at least some of, or all of, the bases 44 of thesecond plurality of projections 36 may have a first width, W3, in adirection generally parallel to the second rotational axis 14. At leastsome of the recesses 38 in areas adjacent to the bases 44 may have asecond width, W4, in a direction generally parallel to the secondrotational axis 14. The first width, W1, may be the same as, differentthan, smaller than, or greater than the second width, W2.

FIG. 4 is a simplified schematic cross-sectional illustration of theportion of the first roll 8 of FIG. 2A intermeshed with the portion ofthe second roll 10 of FIG. 3A. The remainder of outer surface of thefirst roll 8 having the first plurality of projections 20 and the firstplurality of recesses 22 and the remainder of the second roll 10 havingthe second plurality of projections 36 and the second plurality ofrecesses 38 will, in most instances, intermesh in the same fashion, ifdesired. In some instances, it may be desirably to only createthree-dimensional elements and apertures in a central longitudinalstrip, as will be discussed in more detail below. The precursorsubstrate 4 is not illustrated in FIG. 4 for clarity in illustration ofthe tooling, but would be present in the gap between the two rolls 8,10. In FIG. 4, portions of the first plurality of projections 20 of thefirst roll 8 are intermeshed with portions of the second plurality ofrecesses 38 in the second roll 10. Also, portions of the secondplurality of projections 36 of the second roll 10 are intermeshed withportions of the first plurality of recesses 22 of the first roll 8. Insuch a fashion, portions of one or more side walls 28 of the firstdistal portions 24 are brought into close proximity to portions of theshoulders 46 of the second distal portions 40. The side walls 28 and theshoulders 46 together may apply a force to the precursor substrate 4 tocompress the precursor substrate 4 therebetween. When the precursorsubstrate 4 is positioned in the nip between the first roll 8 and thesecond roll 8, the shoulders 46 and portions of the one or more sidewalls 28 may be used to create compressed regions or densified areas inthe precursor substrate 4. The compressed regions or densified areas inthe substrate may aid in resisting compression of three-dimensionalelements. The compression may be classified as reversible elasticdeformation of the precursor substrate 4 (e.g., a nonwoven material).Compression means squeezing air out of a lofty precursor substrate andcausing straightening and/or nesting of the fibers of the precursorsubstrate. Compression does not mean causing, for example, polymer in anonwoven material to begin flowing to fill the air voids and thensolidifying (known as non-reversible elastic deformation).Non-reversible elastic deformation may create rigid areas in theprecursor substrate, thereby reducing the precursor substrates'softness. Thus, reversible elastic deformation is more desirable thannon-reversible elastic deformation in that it provides better softnesswhile still providing resistance to compression of the three-dimensionalelements. Thus, a gap, G, is provided between the side walls 28 and theshoulders 46 to only allow for compression of the precursor substratetherebetween without causing it to melt and solidify.

FIG. 4A is an exploded view of region 4A of FIG. 4. FIG. 4A illustratean example, optional configuration for the shoulders 46 and the sidewalls 28, wherein the shoulders 46 and the side walls 28 each have twooff-set surfaces. Any of the shoulders 46 and the side walls 28disclosed herein may have such off-set surfaces. In other instances, theshoulders 46 and the side walls 28 may not have two off-set surfaces.

The first plurality of projections 20 may not fully engage the secondplurality of the recesses 38 and the second plurality of projections 36may not fully engage the first plurality of the recesses 22. As statedabove, the first plurality of projections 20, namely the points and thefirst distal portions 24, in combination with the second plurality ofrecesses 38, are used to form apertures in the precursor substrate 4.The second plurality of projections 36, namely the second distal ends 42and the second distal portions 40, in combination with the firstplurality of recesses 22 are used to form three-dimensional elements inthe precursor substrate 4. The compressed regions may be formed in thethree-dimensional elements to aid the three-dimensional elements toresist compression, such as compression caused by packaging.

Referring to FIG. 5, at least some of the second plurality ofprojections 36 may have beveled portions 50 intermediate the seconddistal ends 42 and the second distal portions 40. This prevents, or atleast inhibits, the precursor substrate 4 from contacting a sharp cornerand tearing or creating a sharp edge in the precursor substrate 4.Referring to FIG. 6, at least some of the second plurality ofprojections 36 may have rounded corners 52 intermediate the seconddistal ends 42 and the second distal portions 40. This prevents, or atleast inhibits, the precursor substrate 4 from contacting a sharp cornerand tearing or creating a sharp edge in the precursor substrate 4.

FIGS. 7A-7G are top view schematic illustrations of examples ofdifferent configurations of the second plurality of projections 36′. Insuch examples, the second distal portions 40′ may not be the same shapeas the shape of the second distal ends 42′ (see e.g., FIGS. 7B-7G). Inanother example, the second distal portion 40′ may be the same or asimilar shape as the shape of the second distal ends (see e.g., FIG.7A). Referring to FIGS. 7C-7E, the second distal portions 40′ may notfully surround the second central longitudinal axes 48′ of the secondplurality of projections 36′. In such an instance, a compressed regionor densified area in the formed substrate 2 may not fully surround athree-dimensional element. Referring to FIGS. 7E and 7G, the seconddistal portions 40′ may fully surround the second central longitudinalaxes 48′ of the second plurality of projections 36′. In such aninstance, a compressed region or densified area in the formed substrate2 may fully surround a three-dimensional element

FIGS. 8A-8F are top view schematic illustrations of examples ofdifferent configurations of the first plurality of projections 20′. Theside walls 28′ may fully surround the first central longitudinal axis32′ (see e.g., FIGS. 8C, 8E and 8F). In other instances, the side walls28′ may not fully surround the first central longitudinal axis 32′ (seee.g., FIGS. 8A, 8B, and 8D). In some examples, the configuration of theside walls of the first plurality of projections 20 may or may not matchthe configuration of the second distal portions of the second pluralityof projections.

In some instances, the first plurality of projections, from a top view,may have a machine directional length that is shorter than across-directional width due to the speed at which the substrate isproduced to prevent, or at least inhibit distortion in the formedapertures. Stated another way, the machine directional length may beshorter than the cross-directional width such that round apertures areformed. If the machine directional length of the first plurality ofprojections is the same as the cross-directional width, ovate (elongatedin MID) apertures may be formed owing to the speed at which thesubstrate is produced. The second plurality of projections may bedesigned in a similar fashion for the same reason.

FIG. 9 is a cross-sectional view of a portion of a first roll 8 and aportion of a second roll 10 intermeshed with each other. FIG. 9A is across-sectional blown up view of detail 9A of FIG. 18. FIGS. 9 and 9Aillustrate other forms of the portions of the first and second rolls 8,10. In FIGS. 9 and 9A, the same reference numbers reflect the samecomponents as discussed with respect to FIGS. 2-4. The second distalends 42″ of the second plurality of projections 36″ have an arcuate ordome-like shape instead of a flat distal end 42 as illustrated in otherfigures. It is important to note that the first and second rolls of FIG.9 illustrate a form of the rolls 8, 10 where the three-dimensionalelement creation/aperturing occurs only in a middle portion of the rollsto form a central longitudinal strip of three-dimensional elements andapertures in the substrate and to form side portions withoutthree-dimensional elements and apertures, as will be discussed infurther detail below. Selective three-dimensional elementcreation/aperturing may also occur in the machine direction (whether incentral longitudinal strip form or not). Stated another way, in themachine direction, three-dimensional elements/apertures may be createdin a first area, a second area may be free of three-dimensionalelements/apertures, and then a third area may have three-dimensionalelements/apertures. In the machine direction, the first area may be themost upstream and the third area may be the least upstream, with thesecond area being between the first and second areas. In a topsheetexample, three-dimensional elements/apertures may only be created in aback waist region of the topsheet when placed in an absorbent article,for example.

The precursor substrate 4 and thereby the formed substrate 2 may beformed of one or more substrates, for example, one or more nonwovenmaterials, one or more nonwoven materials and one or more film, or oneor more films, for example. If more than one substrates is provided, thesubstrates may be joined together or attached to each other throughmechanical bonding, adhesive bonding, pressure bonding, pressure/heatbonding, welding, thermo-mechanical welding, passing heated air throughboth layers, or by other methods of joining to form the multilayersubstrate 400. Alternatively, the substrates may be formed in subsequentfiber laydown steps, such as a first and a second carding operation fora first type and a second type of staple fibers or two subsequent beamsof spunlaying polymeric filaments comprising additives. The one or moresubstrates may be the same or different in basis weight, hydrophilicity,materials, fibers, density, denier, and/or other properties. If morethan one substrate is present in a precursor substrate, the substratesmay have the same size and shape as the first substrate or may have adifferent size and shape as the first substrate. Stated another way, anadditional substrate may fully overlap the first substrate or may onlypartially overlap the first substrate. The substrates of the precursorsubstrate 4 and the formed substrate 2 may have different colors, suchas colors with different delta E values and/or different L*a*b* values.Some examples may be a white first substrate and a blue secondsubstrate, a light blue first substrate and a dark blue secondsubstrate, or purple first substrate and a blue second substrate, orfirst and third white substrates sandwiching a blue middle substrate.FIG. 10 is a top view of an example precursor substrate that may beconveyed through a nip formed between the first and second rolls 8, 10of the present disclosure. FIG. 11 is a cross-sectional view of theprecursor substrate of FIG. 10 taken about line 11-11. FIG. 12 is across-sectional view of the precursor substrate of FIG. 19 taken aboutline 12-12. FIG. 10 illustrates a precursor substrate 4 with a firstsubstrate 3 and a second substrate 5. The first substrate 3 is widerthan the second substrate 5. The second substrate 5 may be positionedover or under the first substrate 3 when the precursor substrate 4 isconveyed through the nip formed by the first and second rolls 8, 10.Additional substrates of varying width may also be provided, such as athird substrate, for example. In some instances, the second substrate 5,or other substrates, may be discontinuous instead of continuous asshown, such as through the use of a cut and slip process. In such aninstance, the first substrate 3 may be a topsheet and the secondsubstrate 5 may be an acquisition/distribution layer, for example. Thismay be desirable when the second substrate 5 does not need to be or isnot desired to be a full pitch of an absorbent article. As shown fromthe cross-sectional views of FIGS. 11 and 12, the second substrate 5 isnot as wide as the first substrate 3 in the cross-machine direction.Side edges of the first substrate 3 and/or the second substrate 5 maynot be linear and may have arcuate portions, for example. The firstsubstrate 3 may have a basis weight of in the range of about 10 gsm toabout 25 gsm, about 12 gsm to about 20 gsm, about 12 gsm to about 18gsm, about 13 gsm, about 14 gsm, about 15 gsm, about 16 gsm, about 17gsm, specifically reciting all 0.1 gsm increments within the specifiedranges and all ranges formed therein or thereby. The second substrate 5may have a basis weight in the range of about 10 gsm to about 40 gsm,about 15 gsm to about 30 gsm, about 15 gsm to about 25 gsm, about 18gsm, about 22 gsm, about 19 gsm, about 20 gsm, about 21 gsm,specifically reciting all 0.1 gsm increments within the specified rangesand all ranges formed therein or thereby. As an example, the firstsubstrate 3 may be 175 mm wide and the second substrate 5 may be 95 mmwide. In an instance, the first substrate 3 may comprise two side piecesthat are attached to side portions of the second substrate 5, such thata three piece laminate is formed. The first and second substrates may bereferred to as the second and first substrates in various claims,depending on which substrate is being recited first in the claims.

An example precursor substrate may have a first substrate and a secondsubstrate (or any other suitable number of substrate, such as onesubstrate or three substrates). The first substrate may comprise aplurality of first fibers and/or filaments (sometimes referred to hereintogether as “fibers”). The plurality of first fibers may comprise fibersthat are the same, substantially the same, or different in size, shape,composition, denier, diameter, length, type, cross-sectional shape,and/or weight, for example. The second substrate may comprise aplurality of second fibers. The plurality of second fibers may comprisefibers that are the same, substantially the same, or different in size,shape, composition, denier, diameter, length, type, cross-sectionalshape, and/or weight, for example. The plurality of first fibers may bethe same as, substantially the same as, or different than the pluralityof second fibers. Additional substrate may have the same or differentconfigurations.

The first substrate and/or the second substrate may comprise bicomponentfibers having a sheath and a core. The sheath may comprise polyethyleneand the core may comprise polyethylene terephthalate (PET). The sheathand the core may also comprise any other suitable materials known tothose of skill in the art. The sheath and the core may each compriseabout 50% of the fibers by weight of the fibers, although othervariations (e.g., sheath 60%, core 40%; sheath 30%, core 70% etc.) arealso within the scope of the present disclosure. The bicomponent fibersor other fibers that make up the first and/or second substrates may havea denier in the range of about 0.5 to about 10, about 0.5 to about 6,about 0.75 to about 4, about 1.0 to about 4, about 1.5 to about 4, about1.5 to about 3, about 1.5 to about 2.5, or about 2, specificallyincluding all 0.1 denier increments within the specified ranges and allranges formed therein or thereby. Denier is defined as the mass in gramsper 9000 meters of a fiber length. In other instances, the denier of thefibers of the first substrate may be in the range of about 1.5 denier toabout 6 denier or about 2 denier to about 4 denier and the denier of thefibers of the second substrate may be in the range of about 1.2 denierto about 3 denier or about 1.5 denier to about 3 denier, specificallyreciting all 0.1 denier increments within the specified ranges and allranges formed therein or thereby. In certain instances, the fibers ofthe first substrate may be at least 0.5 denier, at least 1 denier, atleast 1.5 denier, or at least 2 denier greater than the denier of thefibers of the second substrate depending at least in part on theparticular acquisition and/or distribution system in use in a certainabsorbent article. By providing the fibers of the first substrate with adenier higher than a denier of the fibers of the second substrate, apore gradient is provided in the liquid permeable substrate. This poregradient may provide better dryness and/or acquisition in the liquidpermeable substrate. The fibers having the larger denier in the firstsubstrate provide larger pores than the fibers having the smaller denierin the second substrate, thereby producing the pore gradient between thesubstrate.

The plurality of first and second fibers may also comprise any othersuitable types of fibers, such as polypropylene fibers, otherpolyolefins, other polyesters besides PET such as polylactic acid,thermoplastic starch-containing sustainable resins, other sustainableresins, bio-PE, bio-PP, and Bio-PET, viscose fibers, rayon fibers, orother suitable nonwoven fibers, for example. These fibers may have anysuitable deniers or denier ranges and/or fiber lengths or fiber lengthranges. In an instance where the plurality of first and second fibersare the same or substantially the same, the plurality of second fibersmay be treated with a hydrophilic agent, such as a surfactant, to causethe plurality of second fibers to become hydrophilic or at least lesshydrophobic. The plurality of first fibers may not be treated with thesurfactant such that they remain in their natural hydrophobic state orthe plurality of first fibers may be treated with a surfactant to becomeless hydrophobic.

The first substrate may have a basis weight in the range of about 10 gsmto about 25 gsm. The second substrate may have a basis weight in therange of about 10 gsm to about 45 gsm. The basis weight of both thefirst and second substrates may be in the range of about 20 gsm to about70 gsm, about 20 gsm to about 60 gsm, about 25 gsm to about 50 gsm,about 30 gsm to about 40 gsm, about 30 gsm, about 35 gsm, or about 40gsm, for example.

The first substrate may have a first basis weight and the secondsubstrate may have a second basis weight. The first and second basisweights may be the same or different. In an instance, the first basisweight may be lower than the second substrate. No matter whetherreferred to as the “first substrate” or the “second substrate” herein,typically the substrate having the narrower cross-directional width mayhave the higher basis weight.

In a form, the basis weight of the precursor substrate 4 may be about 30gsm to about 40 gsm or about 35 gsm. In such an example, the firstsubstrate may have a basis weight in the range of about 10 gsm to about20 gsm, or about 15 gsm, and the second substrate may have a basisweight in the range of about 15 gsm to about 25 gsm, or about 20 gsm. Inanother example, the basis weight of the precursor substrate may beabout 20 gsm. In such an example, the first substrate may have a basisweight of about 10 gsm and the second substrate may have a basis weightof about 10 gsm. In still another example, the basis weight of theprecursor substrate may be about 60 gsm. In such an example, the firstsubstrate may have a basis weight of about 24 gsm, and the secondsubstrate may have a basis weight of 36 gsm. All other suitable basisweight ranges for the first and second 1 substrate and the precursorsubstrates are within the scope of the present disclosure. Accordingly,the basis weight of the substrates and the precursor substrates may bedesigned for specific product requirements.

Specifically recited herein are all 0.1 gsm increments within theabove-specified ranges of basis weight and all ranges formed therein orthereby.

In some instances, it may be desirable to have a higher basis weight inthe first substrate compared to the second substrate. For instance, thefirst substrate's basis weight may be at least about 1 to about 4 times,at least about 1 to about 3.5 times, about 1.5 to about 3 times, about1.5 times to about 3 times, about 2 times, about 2.5 times, or about 3times greater than the second substrate's basis weight. In someinstances, the basis weight of the first substrate may be in the rangeof about 20 gsm to about 30 gsm, and the basis weight of the secondsubstrate may be in the range of about 10 gsm to about 20 gsm, forexample. Specifically recited herein are all 0.1 gsm increments withinthe above-specified ranges of basis weight and all ranges formed thereinor thereby. By providing the first substrate (hydrophobic) with a higherbasis weight than the second substrate (hydrophilic), more hydrophobicmaterial than hydrophilic material is provided in the liquid permeablesubstrate. Upon information and belief, more hydrophobic material andless hydrophilic material in the liquid permeable substrate provides forbetter acquisition and/or dryness. The surface tension of thehydrophilic substrate (first substrate) may be reduced to at leastinhibit the hydrophilic substrate (second substrate) from contaminatingthe hydrophobic substrate (first substrate) (and making it morehydrophilic) upon the liquid permeable substrate receiving one or moregushes.

The fibers may be spunbond fibers, hydroentangled fibers, carded fibers,meltblown fibers, nano fibers (less than 1 micron), or other suitabletypes of fibers. The fibers may be crimped. The fibers may have acircular cross-sections or non-circular shaped cross section, such asovate or trilobal, for example.

In an example, referring to FIG. 10, the first substrate 3 and thesecond substrate 5 may together form a topsheet of an absorbent article.The first substrate 3 may be on the baby-facing surface or thewearer-facing side. The first substrate 3 (wearer-facing side) may behydrophobic and the second substrate 5 may be hydrophilic(garment-facing side) or the second substrate 5 may be hydrophobic(wearer-facing side) and the first substrate 3 may be hydrophilic(garment-facing side). In some configurations, both of the substrates 3,5 (or other substrates) may be hydrophobic or hydrophilic to the samedegree or to different degrees. Either or both of the substrates 3, 5may have the three-dimensional elements and/or apertures describedherein. In an instance where both of the substrates 3, 5 have thethree-dimensional elements and the apertures, the three-dimensionalelements and apertures may be formed in/through both substrates. Whenthe precursor substrate 4 is conveyed through the nip, the twosubstrates 3, 5 (or other substrates) may be joined together by thefirst and second rolls 8, 10 without the use of an adhesive. In otherinstances, adhesives may be used to join the various substrates.

In some instances, bonds or welds 9 may be formed around portions of theperimeter of the second substrate 5 to help join the second substrate 5to the first substrate 3. The bonds 9 may also be formed in other areaswhere the first and second substrates overlap. The bonds 9 may becompressed areas in the first and second substrates 3, 5. The bonds 9may be applied to the first and second substrates (or to additionalsubstrates) upstream of the nip, in the nip (i.e., by the first andsecond rolls 8, 10), or downstream of the nip. Tooling for applying thebonds 9 may be a pair of rolls having nubs on one roll and a flatsurface or nubs on the other roll. If nubs are provided on both rolls,they may come into contact with each other to form the bonds 9. Thefirst and second rolls 8, 10 may comprise the nubs and/or flat surfacesif the bonds 9 are going to be applied in the nip.

In some instances, the substrates produced by the methods and tooling ofthe present disclosure may be used as outer cover materials forabsorbent articles or as other portions of absorbent articles.

The precursor web 4 and/or the formed substrate 2 (after the nip betweenthe first and second rolls 8, 10) may be subjected to a variety oftreatments. Some example treatments are chemical treatments, mechanicaltreatments, and/or heat treatments. Examples of chemical treatments maybe applying one or more lotions, surfactants, vitamins, pH modifiers,inks, enzymes, hydrophilic materials, hydrophobic materials, and/orother substances either before, after, or in the nip between the firstand second rolls 8, 10. These chemical treatments may be sprayed ontothe precursor substrate or substrate, rolled onto the precursorsubstrate or substrate, applied by one or more of the first and secondrolls 8, 10 or portions thereof, and/or may be applied by other methods.In some instances, the chemical treatments may be applied to the firstand/or second plurality of projections 20, 36 and then transferred tothe substrate in the nip. As an example, a hydrophobic composition maybe applied to the precursor substrate 4 upstream of the nip and then thefirst distal portions 24 of at least some of the first plurality ofprojections 20 may be coated with a hydrophilic treatment that may betransferred to perimeters of apertures formed by the projections 20. Insuch an instance, the formed substrate 2 may be primarily hydrophobicbut have hydrophilic areas on or proximate to perimeters of theapertures. Examples of mechanical treatments may be embossing,cross-machine direction tensioning, and/or machine direction tensioningeither before or after the nip. Such mechanical treatments may beapplied by other rolls or other equipment upstream and/or downstreamfrom the first and second rolls 8, 10. Examples of heat treatments maycomprise heating the precursor substrate 4 before the nip, heating theprecursor substrate in the nip, and/or heating the substrate after thenip. The precursor substrate 4 or the formed substrate 2 may be heatedby blowing hot air through the precursor substrate 4 or formed substrate2 (i.e., “air-through), by running the entire precursor substrate 4 orformed substrate 2 through a heat tunnel, by running a surface of theprecursor substrate 4 or substrate 2 over a heated roll (to only heatthe surface) or a nip between two heated rolls (to heat both surfaces),by radiation, and/or by heating the first and/or second rolls 8, 10, forexample. Hot air may also be blown through conduits in one or more ofthe rolls 8, 10, to heat the precursor substrate 4. Heating theprecursor substrate 4 before the precursor substrate 4 enters the nipmay cause the precursor substrate 4 to absorb enough heat to allow theprecursor substrate 4 or polymers in the precursor substrate 4 to flowunder pressure and create bonds or welds to stabilize the apertures 56and/or three-dimensional elements 54. Heating the formed substrate 2after the nip may cause the three-dimensional elements 54 and theapertures 56 to be “set” into the substrate. In some cases, it may bedesirable to input energy into the precursor substrate or substrate toeither aid in the formation of the three-dimensional elements 54 andapertures 56 and/or to help “set” the three-dimensional elements and/orapertures. This input energy may also help to stabilize the substrateand may promote better fiber fusion in the substrate. Providing inputenergy to the substrate may also provide the three-dimensional elementsof the substrate, or the substrate as a whole the ability to betterresist compression due to packaging.

If the precursor substrate 4 is heated upstream of the nip, it may becooled in the nip or downstream from the nip. Cooling may beaccomplished by maintaining the first and second rolls 8, 10 at ambienttemperature, by running the formed substrate 2 over a cooled roll, or bycooling the first and second rolls 8, 10. The first and second rolls 8,10 may be at a temperature cooler than a temperature of the precursorsubstrate. Cooling may also be accomplished in the nip by blowingambient or cooled air into the nip. Cooling may also be accomplished byambient air or by blowing ambient air onto the substrate downstream ofthe nip or by providing a cooling source, such as cooled air blowing onthe substrate or by cooled rolls. Cooling may also be accomplishedthrough cooling in the nip (cooled first and second rolls 8, 10) anddownstream of the nip (cooled rolls, blowing ambient air, or blowingcooled air).

If the precursor substrate 4 is heated in the nip, it may be cooleddownstream of the nip. Cooling may be accomplished downstream of the nipby ambient air, by blowing ambient air, or by providing a source ofcooling, such as blown cooled air or cooled rolls.

Referring now to FIG. 13, a top view of a continuous formed substrate 2is illustrated. This formed substrate 2 is after the three-dimensionalelements 54 and/or the apertures 56 were formed in the formed substrate2 by the first and second rolls 8, 10. The three-dimensional elements 54and apertures 56 are shown generically in FIG. 13 for purposes ofillustration only. The formed substrate 2 may be formed of one or moresubstrates, as referenced herein. The two substrates may have the samecross-machine directional width or a different cross-machine directionalwidth. The cross-machine direction in FIG. 13 is perpendicular to arrow“MD”. In an instance, an additional substrate or a second substrate maybe placed only in a central longitudinal strip 7 in the formed substrate2.

In a single substrate format, or a two or more substrate format, whereall of the substrates have the same cross-machine directional width, thethree-dimensional elements 54 and/or the apertures 56 may be formed onlyin the central longitudinal strip 7 with the areas outside the centrallongitudinal strip 7 being free of the three-dimensional elements 54and/or the apertures 56. As such, a method may comprise only contactingthe central longitudinal strip 7 of the precursor substrate 4 withportions of the first plurality of projections 20, portions of the firstplurality of recesses 22, portions of the second plurality ofprojections 36, and portions of the second plurality of recesses 38. Assuch, the first and second rolls 8, 10 may have the exampleconfiguration illustrated in FIG. 14 with first areas 58 away from acenter of the rolls 8, 10 being free of any projections or any recessesand with second areas 59 proximate to the center of the rolls 8, 10comprising the first and second plurality of projections 20, 36 and thefirst and second pluralities of recesses 22, 38. As a result, thethree-dimensional elements 54 and/or the apertures 56 may only be formedin the central longitudinal strip 7 of the substrate 4. In one instance,a logo, brand name, and/or other indicia 61 may be formed in the sideportions 60 and/or in the central longitudinal strip 7. This logo, brandname, and/or other indicia 61, may be formed using the tooling describedherein or by embossing, for example. In any event, the logo, brand name,or other indicia 61 may have three-dimensional elements or may be formedof three-dimensional elements, recesses, and/or apertures. The logo,brand name, and/or other indicia 61 may also be formed by the weldingunits/bonding units described herein. As an example, one or more weldanvils may take on the shape of the logo, brand name, and/or otherindicia 61 and the weld/welds bond/bonds would be created in that shape.

In a two or more substrate precursor substrate, where one substrate hasa different cross-machine directional width as the other substrate orsubstrates, the three-dimensional elements 54 and/or the apertures 56may be formed only where there is overlap between the substrates, suchas in a central longitudinal strip 7 or in another portion. In such aninstance, a method may comprise conveying a first precursor web in amachine direction, conveying a second precursor web in the machinedirection either under or over the first precursor web. The first andsecond precursor webs may be joined by bonds, through-air bonds,adhesives, or may merely be on contact with each other and joinedtogether in the nip. The first precursor web may have a firstcross-machine directional width and the second precursor web may have asecond, smaller cross-machine directional width. The method may comprisecontacting the precursor substrate and the second precursor substratewith portions of the first plurality of projections, portions of thefirst plurality of recesses, portions of the second plurality ofprojections, and portions of the second plurality of recesses in the nipsubstantially only, or only, where the first precursor substrateoverlaps with the second precursor substrate. The resulting substratewould also have the appearance show in FIG. 13 with two substrates ofmaterial in the central longitudinal strip 7 and one substrate outsidethe central longitudinal strip 7.

Once the three-dimensional elements 54 and/or the apertures 56 areformed in the central longitudinal strip 7 (whether one or moresubstrates), side portions 60, or areas thereof, free of thethree-dimensional elements 54 and/or the apertures 56 may be stretchedin the cross-machine direction to reduce the basis weight of the sideportions 60. If the substrate is used as a topsheet in an absorbentarticle, such as a diaper or adult incontinence article, at least areasof the side portions 60 may be positioned under leg cuffs of theabsorbent article. As such, these areas of the side portions 60, or theentire side portions 60, may not contact a wearer's skin and may not bevisible to a consumer or caregiver. As a result, material savings may beachieved by stretching at least the areas, or the entire side portions,in the cross-machine direction. As an example, if the side portions 60prior to stretching have a basis weight of 15 gsm (grams per squaremeter), the side portions 60 may be stretched in the cross-machinedirection such that their basis weight becomes 10 gsm. Thiscross-machine directional stretching may be accomplished in a number ofways.

Referring to FIGS. 15 and 16, one suitable example way of cross-machinedirectional stretching the side portions 60, or portions thereof, may beaccomplished using a first stretching roll 62 and a second stretchingroll 64. The first and second stretching rolls 62 and 64 may each havemiddle portions 66 that are generally radial without having anythree-dimensional elements. The first stretching roll 62 may comprise afirst plurality of ridges 72 and a first plurality of grooves 74 in theouter portions 68, 70. The second stretching roll 64 may comprise asecond plurality of ridges 76 and a second plurality of grooves 78 inthe outer portions 68, 70. At least some of, or all of, the firstplurality of ridges 62 on the first roll 62 may engage at least some of,or all of, the second plurality of grooves 78 on the second roll 64.Likewise, at least some of, or all of, the second plurality of ridges 76on the second roll 64 may engage at least some of, or all of, the firstplurality of grooves 74 on the first roll 62. The tips 80 of the firstplurality of ridges 72 on the first roll 62 may enter the secondplurality of grooves 78 on the second roll 64 to a certain depth ofengagement “E”. Likewise, the tips 82 of the second plurality of ridges76 on the second roll 64 may enter the first plurality of grooves 74 onthe first roll 62 to the certain depth of engagement, E. The depth ofengagement, E, controls the degree to which the side portions 60 arestretched in the cross-machine direction. A lower depth of engagementmay result in less cross-machine directional stretching and a higherdepth of engagement may result in more cross-machine directionalstretching. As result, the degree of cross-machine directionalstretching of the side portions 60 may be varied according to the depthof engagement, E.

The side portions 60 of the formed substrate 2 may be positionedintermediate the outer portions 68 and 70 on the first and secondstretching rolls 62 and 64. The central longitudinal strip 7 may bepositioned intermediate the middle portions 66 of the first and secondstretching rolls 62 and 64. In such a fashion, the central longitudinalstrip 7 may not be stretched in the cross-machine direction while theside portions 60 may be stretched in the cross-machine direction.Further, in this fashion, the central longitudinal strip 7 may notactually be in contact with the middle portions 66 of the rolls 62, 64so that the three-dimensional elements 54 within the centrallongitudinal strip 7 are not compressed.

In a two substrate configuration, with the second substrate only beingpresent in the central longitudinal strip, a method may comprisestretching the first substrate in a cross-machine direction where, oronly where, the first substrate is free of overlap with a secondsubstrate (i.e., outside the central longitudinal strip). Thisstretching step may occur upstream of the nip or downstream of the nip.

Again referring to FIG. 13, the formed substrate 2 (whether havingthree-dimensional elements 54 and apertures 56 in a central longitudinalstrip or throughout the formed substrate 2) may be cut to a final pitchfor a component of an absorbent article, such as a topsheet, anacquisition layer, a distribution layer, or an outer cover nonwovenmaterial, for example. The formed substrate 2 may be cut along line 88.Although line 88 is illustrated as perpendicular to the machinedirection, those of skill in the art will recognize that the actual cutpath may not perpendicular to the machine direction, but instead may betransverse to the machine direction to account for the speed of themoving substrate during cutting. Stated another way, the cut path may beangled with respect to the cross-machine direction to account forsubstrate speed on the absorbent article manufacturing line. The cutsubstrates may then be joined to a portion of an absorbent article onthe absorbent article manufacturing line.

Referring again to FIG. 13, the central longitudinal strip 7 may be asubstrate placed on another substrate. In an example of a topsheet, thetopsheet may have a solid, generally planar substrate on agarment-facing surface thereof and a patch of the central longitudinalstrip 7 on a wearer-facing surface thereof. The patch may comprise aprecursor substrate run through the nip between the first and secondrolls 8, 10 thereof and containing the three-dimensional elements 54and/or the apertures 56. The patch may or may not be the full absorbentarticle pitch. Stated another way, the patch may not be the full lengthof the topsheet and/or the absorbent article. Also, the patch may or maynot be the full width of the topsheet.

FIG. 17 is a schematic illustration of a three roll process of creatinga substrate having a first substrate with three-dimensional elements andapertures and a second generally planar substrate with only apertures.FIG. 18 is a cross-sectional view taken about detail 18 of FIG. 17. InFIG. 17, the first roll 208 and the second roll 210 may be the same asthe first and second rolls 8, 10 described herein are illustrated simplyin FIG. 17. The third roll 212 may be a roll having a radial outersurface 214 with a plurality of recesses 216 defined therein. Therecesses in the third roll 212 may the same as or similar to therecesses of the first plurality of recesses 22 in the first roll 8. Thethird roll 212 may not have any projections. In such a three rollprocess, a precursor substrate 204 may be conveyed between the first andsecond rolls 208 and 210 to form the three-dimensional elements andapertures described herein. The precursor substrate 204 may thencontinue to rotate around the first roll 208 with the first plurality ofprojections 20 engaged with the precursor substrate 204. The secondprecursor substrate 205 is conveyed into a nip formed between the firstroll 208 and the third roll 212. The projections 20 then enter therecesses 216 in the third roll to puncture apertures in the secondprecursor substrate 205 in the nip between the first roll 208 and thethird roll 212. An example resulting structure is illustrated in the nipof FIG. 18.

The second substrate 205 may be generally planar with apertures afterbeing conveyed through the nip between the first and third rolls 208 and212. The resulting structure is a two substrate composite with athree-dimensional top substrate 204 and a generally planar bottomsubstrate 205. Apertures will extend through both of the substrates 204,205 as a result of the first and third rolls 208 and 212. As an examplethe three-dimensional top substrate 204 may be a topsheet and thegenerally planar bottom substrate 205 may be an acquisition layer. Asanother example the three-dimensional top substrate 204 may be part of atopsheet and the generally planar bottom substrate 205 may be part of anacquisition layer. The three-dimensional top substrate 204 and thegenerally planar bottom substrate 205 may each be formed of one or moresubstrates or materials.

The two substrate laminate provides integrity to the structure and locksin the three-dimensional elements and apertures. The first and secondsubstrates 204, 205 may be free of thermally shrinkable fibers. One ormore adhesives may be sprayed onto or otherwise applied to the secondprecursor substrate 205 to cause it to adhere to the first precursorsubstrate 204 in the nip. In some instances, adhesives may not berequired between the first and second precursor substrates 204, 205. Insuch an instance, the forces of the nip between the first and thirdrolls and the aperturing process may be enough to join the twosubstrates.

FIG. 19 is a top perspective view of an example three-dimensional,apertured substrate produced by the first and second rolls 8, 10 of thepresent disclosure. FIG. 20 is a top view of an examplethree-dimensional, apertured substrate produced by the first and secondrolls 8, 10 of the present disclosure. FIG. 21 is a back view of theexample three-dimensional, apertured substrate of FIG. 20. FIG. 22 is across-sectional view taken through the example three-dimensional,apertured substrate of FIG. 20.

FIG. 23 illustrates a simplified schematic cross-sectional exampleillustration of the rolls 8, 10 that are configured primarily forcreating three-dimensional elements and compressed regions in theprecursor substrate 4 and not apertures. In FIG. 23, distal ends 126 ofthe first plurality of projections 120 may form flat or rounded surfacesso as to not aperture the precursor substrate. The second plurality ofprojections 36 and the second roll 10 generally may remain the same asdescribed above. FIG. 25 illustrates a simplified schematiccross-sectional example illustration of the rolls 8, 10 of FIG. 23 withless engagement with each other. This level of engagement may be usedfor thicker substrates, for example, or when less compression isdesired.

FIG. 24 illustrates a simplified schematic cross-sectional exampleillustration of the rolls 8, 10 that are configured primarily forcreating apertures and compressed regions in the precursor substrate 4and not three-dimensional elements or more limited (e.g., less height)three dimensional features compared to the rolls 8, 10 of FIG. 4. InFIG. 24, second distal ends 142 of the second plurality of projections136 may form flat or rounded surfaces, for example to eliminatethree-dimensional element formation or to reduce the height of thethree-dimensional elements in the precursor substrate. The firstplurality of projections 20 and the first roll 8 generally may remainthe same as described above. FIG. 26 illustrates a simplified schematiccross-sectional example illustration of the rolls 8, 10 of FIG. 24 withless engagement with each other. This level of engagement may be usedfor thicker substrates, for example, or when less compression and/orsmaller apertures are desired.

FIG. 27 illustrates a simplified schematic cross-sectional exampleillustration of the rolls 8, 10, like FIG. 4, but with more separationbetween the rolls 8, 10. In such an instance, the rolls 8, 10 may be setapart from each other such that only apertures and three-dimensionalelements are formed in the precursor substrate, without compressedregions being formed between the side walls 28 and the shoulders 46. Insome instances, portions of the precursor substrate 4 may be slightlycompressed between the side walls 28 and the shoulders 46, but not tothe extent of compression that would result from the rolls 8, 10 of FIG.4. As such, the center-to-center distance of the first centrallongitudinal axis 32 of the first roll may be adjusted with respect tothe second central longitudinal axis 32 of the second roll to determinethe amount of compression in portions of the precursor substrate 4between the side walls 28 and the shoulders 46. In some instances, morecompression may be desired and, in other instances, less compression maybe desired. The thickness of the precursor substrate 4 may also be afactor to consider in setting the center-to-center distance of the rolls8, 10. This concept of setting the center-to-center distance of therolls may also apply to any of the other example roll configurations setforth herein.

FIG. 28 illustrates a simplified schematic cross-sectional exampleillustration of a portion of a first roll 8 intermeshed with a portionof a second roll 10. FIG. 28A is an exploded view of region 28A in FIG.28. The second roll 10 may be substantially the same as, or the same as,the second roll 10 of FIG. 26 or 27. At least some of, or all of, theprojections 20 may comprise first distal portions 24 comprisingelongated aperturing structures comprising side walls 28. The side walls28 may have a first portion 150 having a first angle and a secondportion 152 having a second angle. The angles are measured relative to acentral longitudinal axis 32 of a projection 20. The second portion 152may be more proximal to the first distal end 26 or point than the firstportion 150. The first angle may be lower than or steeper than thesecond angle. The first angle of the first portion 150 may be in therange of about 20 degrees to about 50 degrees, about 25 degrees to about40 degrees, about 30 degrees to about 40 degrees, about 35 degrees,about 36 degrees, or about 37 degrees, specifically reciting all 0.1degree increments within the specified ranges and all ranges formedtherein or thereby. The second angle of the second portion 152 may be inthe range of about 30 degrees to about 60 degrees, about 35 degrees toabout 55 degrees, about 40 degrees to about 50 degrees, about 46degrees, about 47 degrees, or about 48 degrees, specifically recitingall 0.1 degree increments within the specified ranges and all rangesformed therein or thereby. By having a smaller angle or steeper sidewallin the first portion 150 and a larger angle and less steep sidewall inthe second portion 152, the overall longitudinal length of theprojections 20 may be shorter compared to a projection having a firstdistal portion with only one angle. Shorter projections allow for easierengagement between the first and second rolls 8, 10. Any of the examplerolls configured for aperturing may have the features of the firstplurality of projections 20 described in this paragraph in reference toFIGS. 28 and 28A. Further, the features of the first plurality ofprojections 20 may be used when merely making apertures and notthree-dimensional projections (e.g., FIGS. 24 and 26).

The shoulders 46 may taper inwards toward the point of the firstplurality of projections 20 or may have the same angle as the firstportion 150.

The various rolls may be formed by materials that have good thermalconductivity and that are easy to machine. Example materials includecooper, aluminum, and brass, for example. In some instances, the rollsmay be steel or hardened steel. The rolls may have various surfacecoatings to reduce wear.

Laminates

Laminates of two or more substrates may be formed using the methods andtooling described herein. These laminates may resist delamination owingat least to the provided welds. At least some of the laminate may alsoresist compression, such as in-bag compression of three-dimensionalelements. For example, a laminate like those illustrated in FIGS. 10-14may be formed. The laminates may comprise three-dimensional elementsand/or apertures in at least one substrate. In some instances, thelaminates may comprise three-dimensional elements in only one substrateand apertures through both substrates, with one substrate beinggenerally planar. The apertures in both of the substrates may be formedat the same time. The substrates of the laminates may have the samedimensions or may have different dimension. In an instance, referring toFIGS. 10-12, and as described above, a first substrate 3 may have afirst cross-directional width and a second substrate 5 may have a secondcross-directional width. The first cross-directional width may begreater than the second cross-directional width, so that when overlappedand/or combined, the second substrate 5 may form a central strip on thefirst substrate 3 as illustrated in FIGS. 10-14. The firstcross-directional width may also be larger than or the same as thesecond cross-directional width. The “first substrate” and the “secondsubstrate” may refer to the substrate 3 or the substrate 5 in the claimsdepending on which substrate is recited first. In an absorbent articlecontext, the laminates may form a topsheet, may form atopsheet/acquisition material laminate, and/or may form atopsheet/second topsheet laminate, for example. The laminates may alsoform outer cover nonwoven materials, or other materials of absorbentarticles. In an outer cover context, the substrates may have the samedimensions.

As mentioned herein, at times laminates may have a tendency todelaminate if only run through the rolls illustrated in, for example,FIGS. 2-4, even with the compressed regions. As such, it may bedesirable to have additional joining between the various substrates in alaminate. One way developed by the present inventors is to add welds,such as thermo-mechanical welds, for example, between the substrates toprevent, or at least inhibit, delamination of the substrates. Thesewelds allow the fibers of the various substrates in the laminate tosoften and/or at least partially melt, allowing a portion of a firstsubstrate to become attached to a portion of at least a second substratein a weld area. These welds may comprise ultrasonic welds, heat/pressurebonds, pressure bonds, heat bonds, hot air welds, and/or other suitablewelds. A photograph of ultrasonic welds 200 in a laminate comprisingthree-dimensional elements, apertures, and compressed regions isillustrated in FIG. 29.

The welds may be formed in any suitable patterns in the laminates. Aweld may be a single area of joinder or refer to multiple areas ofjoinder in a proximate location (see e.g., FIGS. 34A and 34B). At times,the welds may be registered with, for example, distal ends and/or sidewalls of the three-dimensional elements, registered with perimeters ofapertures, and/or registered with other portions of the laminate. Atother times, the welds may be unregistered and may be randomly orientedwithin the laminates.

Referring to FIG. 30, an example cross-sectional view of welds 300 on aportion of a three-dimensional apertured, two substrate laminate isillustrated. The welds 300 may be any of the weld types discussedherein. The welds 300 may be registered at the tops 302 of thethree-dimensional elements 304, for example. More than one welds 300 maybe positioned in the tops 302 of the three-dimensional elements 304. Thelaminate may have more than two substrates and may or may not beapertured.

Referring to FIG. 31, an example cross-sectional view of welds 400 on aportion of a three-dimensional apertured, two substrate laminate isillustrated. The welds 400 may be any of the weld types discussedherein. The welds 400 may be registered on side walls 402 of thethree-dimensional elements 404. More than one weld 400 may be positionedin each three-dimensional element 400. The laminate may have more thantwo substrates and may or may not be apertured.

Referring to FIG. 32, an example cross-sectional view of welds 500 on aportion of a three-dimensional apertured, two substrate laminate isillustrated. The welds 500 may be any of the weld types discussedherein. The welds 500 may be unregistered and may be located in sidewalls 502 and/or tops 504 of the three-dimensional elements 506. Morethan one weld 500 may be positioned in each three-dimensional element500. The laminate may have more than two substrates and may or may notbe apertured.

Referring to FIGS. 5 and 6, merely as examples, welds may be formed inthe three-dimensional elements, or other areas of the laminates, byplacing weld anvils 211 on the second plurality of projections 36 ineither or both of the second distal ends 42 and the second distalportions 40. Further description will follow on how the welds areformed. The weld anvils 211 may also be placed in other locations on thevarious tooling to locate the welds in other locations of the laminates.The weld anvils may be configured to receive energy from a welding unit.

The welds may have any suitable shape, such as rectangular, rounds,ovate, conical, square, triangular, half-moon shaped, hearts, forexample. The welds may have any suitable area, aspect ratios, height,length, and width. In some instances, the welds may be raised fromsurfaces of the tooling.

Referring to FIG. 33, an example of a simplified version of a weldingunit in combination with a roll with weld anvils, in the form of anultrasonic welding unit 600, is illustrated. The ultrasonic welding unit600 may comprise an ultrasonic horn 602 and a roll 604 having aplurality of weld anvils 606. The weld anvils 606 may have any suitablepattern, size, shape, and/or area. The roll 604, in some instances, maybe the second roll 10, as described herein, may be the third rolldescribed below, or may be other roll, for example. Two or moresubstrates 608 to be joined may be conveyed intermediate the weld anvils606 and the ultrasonic horn 602 to create the welds 610. The ultrasonichorn 602 may be configured to impart ultrasonic energy to the substrates608 against the weld anvils 606. The various weld anvils 606 may beidentical to or substantially identical to each other or different fromeach other. In some configurations, the weld anvils 606 may comprise apattern element with a patterned surface that defines a continuouscrossing line pattern and/or various other shapes, such as disclosed inU.S. Pat. No. 9,265,672. It is to be appreciated that the patternsurface, such as discussed above, may be flat and/or may also compriseregions defined by relatively high and relatively low elevations.

With continued reference to FIG. 33, energy may be applied to theultrasonic horn 602 to create resonance of the ultrasonic horn atfrequencies and amplitudes so that the ultrasonic horn vibrates rapidlyin a direction generally perpendicular to the substrates 608 beingconveyed past the ultrasonic horn 602. Vibration of the ultrasonic horngenerates heat to melt and join the substrates 608 together in areassupported by the weld anvils 606. Thus, the welds 610 may have shapesthat correspond with and may mirror shapes of the weld anvils 606. It isto be appreciated that aspects of the ultrasonic welding units may beconfigured in various ways, such as, for example, linear or rotary typeconfigurations, and such as disclosed for example in U.S. Pat. Nos.3,113,225; 3,562,041; 3,733,238; 5,110,403; 6,036,796; 6,508,641; and6,645,330. In some forms, the ultrasonic welding device may beconfigured as a linear oscillating type sonotrode, such as for example,available from Herrmann Ultrasonic, Inc. In some configurations, thesonotrode may include a plurality of sonotrodes nested together in thecross direction CD. The welding unit may also be configured in variousother ways, such as for example, the welding devices and methodsdisclosed in U.S. Pat. Nos. 4,854,984; 6,248,195; 8,778,127; and9,005,392; and U.S. Patent Publication Nos. 2014/0377513 A1; and2014/0377506 A1.

FIGS. 34A-34D illustrate three-dimensional, apertured, laminates 700with various example weld patterns 702. FIG. 34A illustrates a weldpattern 702 that forms a plurality of welds around the apertures. FIG.34B illustrates a weld pattern 702 that forms a plurality of welds onside walls of the three-dimensional elements. FIG. 34C illustrates aweld pattern 702 that forms single welds in other areas of the laminatethan in three-dimensional elements. FIG. 34D illustrates a weld pattern702 that forms single welds at a top of three-dimensional elements. Insome instance, more than one of these weld patterns or other weldpatterns may be combined with each other. Other suitable weld patternsare also within the scope of the present disclosure.

FIG. 35 illustrates a three-roll configuration for producing athree-dimensional laminate that reduces delamination between two or moresubstrates. A first roll 708 may be the same as, or substantially thesame as, the first roll 8 described herein. A second roll 710 may be thesame as, or substantially the same as, the second roll 10 describedherein. A third roll 712 may also be provided. The first roll 708 mayhave a first rotational axis 709. The second roll 710 may have a secondrotational axis 711. The third roll 712 may have a third rotational axis713. All of the rotational axes 709, 711,713 may extend parallel to, orsubstantially parallel to, each other. The third roll 712 may comprise aradial outer surface 714, a plurality of weld anvils 716 on or extendingfrom the radial outer surface 714, and a plurality of recesses 718defined in the radial outer surface 714. FIG. 35A is a detail view takenfrom detail 35A in FIG. 35 showing the engagement of the first roll 708and the third roll 712. FIG. 35B is a detail view taken from detail 35Bin FIG. 35 showing the engagement of the first roll 708 and the secondroll 710. In FIG. 35A, it can be seen how first distal portions 724 of afirst plurality of projections 720 of the first roll 708 engage therecesses 718 in the third roll 712. A welding unit, for example anultrasonic welding unit 722, may be provided proximate to the third roll712. The ultrasonic welding unit 722 may function in conjunction withthe weld anvils 716 as described with reference to FIG. 33.

In this three-roll configuration, a first substrate 734 and at least asecond substrate 736 may be conveyed on an absorbent articlemanufacturing line in the machine direction. The first and secondsubstrates may have different or the same cross-directional widths,basis weights, and/or materials, fibers, and/or hydrophobic/hydrophilicproperties, for example, as described herein. The first and secondsubstrates may be overlapped with each other to form an area of overlapbetween the first and second substrates. The first and second substratesmay be conveyed on the third roll 712 between the weld anvils 716 andthe ultrasonic welding unit 722 such that ultrasonic welds 735 may beformed between the first and second substrates in the area of overlap tocause them to join together. The joined laminate of the first and secondsubstrates may then be conveyed through a first nip 715 formed betweenthe first roll 708 and the third roll 712. The first distal portions 724of the first plurality of projections 720 of the first roll 708 mayaperture at least the area of overlap between the first and secondsubstrates. The first and second substrates 734, 736 may travelpartially around the first roll 708, with the apertures in the laminatestill being engaged with the first plurality of projections 720 of thefirst roll 708, and be conveyed through a second nip 717 formed betweenthe first roll 708 and the second roll 710. The second nip 717 betweenthe first roll 708 and second roll 710 may be the same or similar tothat described above with respect to rolls 8 and 10.

The resulting structure may be an at least two substrate laminate withan area of overlap (and possibly other areas) having three-dimensionalelements, apertures, and welds. Compressed regions, as described above,may also be present in the area of overlap (and possibly other areas).Areas in the laminate outside the area of overlap may be generallyplanar (and may not comprise apertures, compressed regions,three-dimensional elements, and/or welds) or may comprisethree-dimensional elements, apertures, compressed regions, and/or welds.

The three-roll configuration of FIG. 35 may be used to form the weldpatterns illustrated in FIGS. 34A-34D, for example.

Referring to FIG. 36, a fourth roll 728 may be provided proximate to thethird roll 712 of FIG. 35 instead of the ultrasonic welding unit 722.The first roll 708 and the second roll 710 may remain the same, orsubstantially the same. The fourth roll 728 may have a fourth rotationalaxis 721. The fourth rotational axis 721 may extend in a directiongenerally parallel to, or parallel to, the third rotational axis 713 ofthe third roll 712 to form a nip 723 intermediate the third roll 712 andthe fourth roll 728. The fourth roll 728 may be a high pressure bondingroll configured to produce welds 735′ that are bonds when protrusions730 extending from a radial outer surface 732 of the fourth roll 728press against the weld anvils 716 on the third roll 712. These highpressure bonds may or may not produce heat through the mechanicalbonding action.

It is sometimes desirable to join the three-dimensional substrates orlaminates of the present disclosure to a generally planar substrate toform a laminate. The generally planar substrate may or may not beapertured. Referring to FIG. 37, a three-roll configuration isillustrated that is configured to produce a laminate with one or morethree-dimensional substrates 740 and one or more generally planarsubstrates 742. The first roll 708 may be the same as described above.The second roll 710 may be the same as described above, although in adifferent location. The third roll may be similar to the third roll 712described above, but may or may not have the weld anvils 716. FIG. 37A,which is a detail view taken from detail 37A of FIG. 37, illustrates theengagement of the first roll 708 and the second roll 710. FIG. 37B,which is a detail view taken from detail 37B of FIG. 37, illustrates theengagement of the first roll 708 and third roll 712.

With continued reference to FIG. 37, the first substrate 740 is conveyedbetween the nip 744 between the first roll 708 and the second roll 710to form three-dimensional elements and apertures in the first substrate740. The first substrate 740 may comprise one or more substrates. Ifmore than one substrate is provided, the substrates may have the same ordifferent cross-directional widths, basis weights, materials, fibers,hydrophobic/hydrophilic properties, and/or other properties, asdescribed herein. The first substrate 740 is then conveyed partiallyaround the first roll 708 and through a second nip 746. The secondgenerally planar substrate 742 is also fed into and through the secondnip 746. In, or proximate to, the second nip 746, the first substrate740 is at least partially overlapped with, or fully overlapped with, thesecond generally planar substrate 742. In such a fashion, both of thefirst and second substrates 740,742 may be co-apertured to form laminatecomprising a three-dimensional substrate and a generally planarsubstrate. By having a three-dimensional substrate joined to a generallyplanar substrate, the three-dimensional elements may better resistcompression in that they are locked into position through theirattachment to the generally planar substrate.

Prior to the second generally planar substrate 742 being conveyed intothe second nip 746, adhesive may be applied by an adhesive dispenser 743to the second substrate 742 on the side of the second substrate thatwill be in a facing relationship with the first substrate 740 in thesecond nip 746. Such adhesive may comprise one or more hot meltadhesive, or other suitable adhesives. The adhesive may prevent, or atleast inhibit, delamination of the first substrate 740 and the secondsubstrate 742.

Either in addition to the adhesive, or in lieu of the adhesive, awelding unit 722 (shown in dash) may be positioned proximate to thethird roll 712. The welding unit 722 may be an ultrasonic welding unit,as described above with respect to FIGS. 33 and 35. The welding unit maycreate welds in conjunction with weld anvils 716 on the third roll 712,as described above. In such an instance, the first and second substrates740, 742 would exit the three-roll process downstream of the weldingunit 722 (as shown in dash).

Referring to FIG. 38, a four-roll configuration for creating a laminatecomprising the first substrate 740 and the second generally planarsubstrate 742 of FIG. 37 is illustrated. Other than its position, afourth roll 728 may be the same as or substantially similar to thefourth roll 728 described above with respect to FIG. 36, and may have afourth rotational axis 721. The fourth roll 728 may work in conjunctionwith the weld anvils 716 on the third roll 712 to create bonds 735′ inthe laminate. This four-roll configuration may be used to create theweld patterns illustrated in FIGS. 34A and 34C, for example. A fourthnip 737 may be formed intermediate the fourth roll 728 and the thirdroll 712.

FIG. 38A is a schematic illustration of a two roll configuration forproducing a three-dimensional laminate, or a laminate, havingthree-dimensional elements, apertures, and/or welds. In some instances,only three-dimensional elements and welds may be formed as describedherein. In other instances, only apertures and welds may be formed asdescribed herein. FIG. 38B is a detail view of section 38B of FIG. 38A.The first roll 708 may be the same as, or substantially the same as, thefirst roll of FIG. 37 and the second roll 710 may be the same as, orsubstantially the same as, the second roll 710 of FIG. 37. A firstsubstrate 750 and at least a second substrate 752 may be conveyed ontothe second roll 710 and through a nip 754 formed between the first andsecond rolls 708, 710. The first and second substrates 750, 752 may havethe same cross-directional widths or different cross-directional widths,as described herein. A welding unit 722 may be positioned proximate tothe second roll 710. At least some of, or all of, the second pluralityof projections 36 may have weld anvils 211 positioned thereon, formedtherein, and/or extending therefrom. Other example positions for weldanvils 211 are also illustrated in FIGS. 5 and 6. The weld anvils mayhave any suitable size and/or shape. The weld anvils 211 may work inconjunction with the welding unit 722 as described herein to createwelds 756 between the first substrate 750 and the second substrate 752.Instead of the weld anvils 211 and the welding unit 722, a bonding unit,such as the roll 728 of FIG. 36, may be positioned proximate to thesecond roll 710. Protrusions, like protrusions 732 of FIG. 36, mayengage distal ends of at least some of the second plurality ofprojections 36 to form welds or bonds between the first and secondsubstrates 750, 752. The first and second substrates 750, 752 may firstbe conveyed onto the second roll 710 past the welding unit 722 such thatwelds may be created between the first and second substrates 750, 752.The first and second substrates 750, 752 may then be conveyed throughthe nip 754 such that apertures and/or three-dimensional elements areformed in the first and second substrates 750, 752. A resulting laminatewith three-dimensional elements, apertures, and/or welds may be formed.

In FIGS. 35-38C, the apertures and three-dimensional elements are notillustrated in the produced laminates for ease of illustration.

Referring generally to FIGS. 38A and 38B, an apparatus may comprise afirst roll 708 having a first radial outer surface and a firstrotational axis 709 and a second roll 710 having a second radial outersurface and a second rotational axis 711. The first rotational axis 709may be positioned generally parallel to the second rotational axis 711to form a nip 754 between the first roll 708 and the second roll 710.The first roll 708 may comprise a first plurality of projectionsextending from the first radial outer surface and a first plurality ofrecesses extending into the first radial outer surface. The second roll710 may comprise a second plurality of projections extending from thesecond radial outer surface and a second plurality of recesses extendinginto the second radial outer surface. The first plurality of projectionsmay be configured to at least partially engage the second plurality ofrecesses and the second plurality of projections may be configured to atleast partially engage the first plurality of recesses. The firstplurality of projections may comprise first distal portions comprisingfirst distal ends. At least some of the distal ends may form a point.The first plurality of projections may be configured to form aperturesin a substrate or laminate being conveyed through the nip. The secondplurality of projections may comprise second distal portions comprisingsecond distal ends. At least some of second distal ends may comprisedomes, arcuate portions, and/or flat surfaces. The second plurality ofprojections may be configured to form three-dimensional elements in thesubstrate or laminate being conveyed through the nip. The second distalends may comprise anvil welds or anvils. A welding unit 722 or a bondingroll may be positioned proximate to the second roll 710 and may beconfigured to interact with at least some of the anvil welds (weldingunit) or anvils (bonding roll) to form welds or bonds in the substrateor laminate.

FIG. 38C is a schematic illustration of a three roll configuration forproducing a three-dimensional laminate having three-dimensionalelements, apertures, and welds. In some instances, onlythree-dimensional elements and welds may be formed as described herein.In other instances, only apertures and welds may be formed as describedherein. A first substrate 768 and at least a second substrate 770 may beconveyed on an absorbent article manufacturing line. The first andsecond substrates 768, 770 may have the same cross-directional width ormay have a different cross-directional width. In FIG. 38C, the weldingunit 722 and roll 760 may be distinct and separate from the first roll708 and the second roll 710. The first and second rolls 708, 710 may bethe same as, or substantially the same as, the first and second rolls708, 710 of FIG. 38 and the roll 760 may be similar to the roll 728 ofFIG. 38. The welding unit 722 may be as described herein. The roll 760may comprise a radial outer surface 762 and a plurality of protrusions764 extending from the radial outer surface 762. Each of, or some of theplurality of protrusions 764 may comprise one or more anvil welds (seee.g., element 211 of FIG. 38B). The welding unit 722 may be configuredto interact with the anvil welds on at least some of the plurality ofprotrusions 764 to form welds 766 in the laminate. In some instances,the roll 760 may have anvil welds on the radial outer surface 762 and befree of the protrusions 764. Instead of the welding unit 722, an anvilroll may be used in conjunction with the roll 760, such that theprotrusions 764 form bonds in the first and second substrates 768 and770. The anvil roll may have generally planar radial outer surface ormay have protrusions like the protrusions 764 on roll 760 that engagewith each other to form the bonds.

In any configuration, the first and second substrates 768, 770 may beconveyed on an absorbent article manufacturing line intermediate theroll 760 and the welding unit 722 or between the roll 760 and an anvilroll. Welds or bonds 766 may be formed between the first and secondsubstrates 768, 770 to form a laminate. The joined laminate may then beconveyed through a nip 772 between the first and second rolls 708, 710to form three-dimensional elements and/or apertures in the laminate. Thedistance between midpoints of the protrusions 764 and the distancebetween the midpoints of the second plurality of projections 36 may bethe same so as to align the welds/bonds with distal ends or distalportions of the three-dimensional elements in the laminate (i.e., aphase registered pattern of bonds and/or welds). Alternatively, weldanvils may be formed on the roll 760 such that the welds are alignedwith perimeters of apertures in the laminate. The bonds/welds could alsobe registered in other portions of the laminate.

Methods

The present disclosure is directed, in part, to a method of making athree-dimensional laminate on an absorbent article manufacturing line.The method may comprise conveying a first substrate in a machinedirection on the absorbent article manufacturing line, conveying asecond substrate in the machine direction on the absorbent articlemanufacturing line, and at least partially overlapping the firstsubstrate with the second substrate to form an area of overlap betweenthe first substrate and the second substrate. The method may compriseproviding a first roll having a first rotational axis, and providing asecond roll having a second rotational axis. The first rotational axisand the second rotational axis may be positioned generally parallel toeach other to form a first nip between the first and second rolls. Themethod may comprise providing a third roll having a third rotationalaxis. The third rotational axis and the first rotational axis may bepositioned generally parallel to each other to form a second nip betweenthe first and third roll. The method may comprise providing a pluralityof weld anvils on the third roll, providing a welding unit proximate tothe third roll, and forming welds in the first and second substrates inthe area of overlap using the welding unit. The method may comprisecreating the three-dimensional laminate of the first and secondsubstrates in the first nip by: forming three-dimensional elements inthe first and second substrates in the area of overlap between the firstsubstrate and the second substrate, and forming apertures in the firstand second substrates in the area of overlap in portions free of thethree-dimensional elements.

The welding unit may comprise an ultrasonic horn or bonding roll. Thebonding roll may have a fourth rotational axis that may be positionedgenerally parallel to the third rotational axis of the third roll. Thethird roll may comprise a plurality of recesses defined in a radialouter surface of the third roll. The weld anvils may be positioned onthe radial outer surface of the third roll or may extend radiallyoutwardly from the radial outer surface of the third roll.

The method may comprise joining the three-dimensional laminate with aportion of an absorbent article on the absorbent article manufacturingline, such as a chassis of an absorbent article without a topsheet.

The first substrate may have a first cross-directional width. The secondsubstrate may have a second cross-directional width. The firstcross-directional width may be different than, the same as, less than,or greater than, the second cross-directional width.

The method may comprise forming compressed regions in thethree-dimensional elements in the first nip.

The first roll may comprise a first radial outer surface, and a firstplurality of projections extending at least partially outwardly from thefirst radial outer surface. The first plurality of projections may beconfigured to form the apertures in the area of overlap between thefirst and second substrates. The first roll may comprise a firstplurality of recesses defined in the first radial outer surface, andfirst distal portions of at least some of the first plurality ofprojections forming elongated aperturing structures comprising sidewalls, and first distal ends of the at least some of the first pluralityof projections forming a point.

The second roll may comprise a second radial outer surface, and a secondplurality of projections extending at least partially outwardly from thesecond radial outer surface. The second plurality of projections may beconfigured to form the three-dimensional elements in the areas ofoverlap between the first and second substrates. The second plurality ofprojections may comprise second distal portions and second distal ends.The second roll may comprise a second plurality of recesses defined inthe second radial outer surface. At least some of the second distalportions may comprise shoulders.

The method may comprise rotating the first roll in a first directionabout the first rotational axis, rotating the second roll in a second,opposite direction about the second rotational axis, and rotating thethird roll in the second, opposite direction about the third rotationalaxis. The third roll may have a third plurality of recesses defined in athird radial outer surface of the third roll. The method may compriseintermeshingly engaging portions of the first plurality of projectionswith portions of the third plurality of recesses in the second nip,intermeshingly engaging portions of the first plurality of projectionswith portions of the second plurality of recesses in the first nip, andintermeshingly engaging portions of the second plurality of projectionswith portions of the first plurality of recesses in the first nip.

The method may comprise applying a chemical treatment to the firstsubstrate and/or the second substrate after the first and secondsubstrates are conveyed through the first nip.

The method may comprise heating the first substrate and/or the secondsubstrate prior to the first and second substrates being conveyedthrough the second nip and/or the first nip.

The method may comprise heating the first roll, the second roll, and/orthe third roll.

The method may comprise heating the first and/or second substrates inthe first nip and/or the second nip.

The present disclosure is directed, in part, to a method of making athree-dimensional laminate on an absorbent article manufacturing line.The method may comprise conveying a first substrate in a machinedirection on the absorbent article manufacturing line, conveying asecond substrate in the machine direction on the absorbent articlemanufacturing line, providing a first roll having a first rotationalaxis, and providing a second roll having a second rotational axis. Thefirst rotational axis and the second rotational axis may be positionedgenerally parallel to each other to form a first nip between the firstand second rolls. The method may comprise creating in the first nip:three-dimensional elements in the first substrates, and apertures in thefirst substrate in portions free of the three-dimensional elements. Themethod may comprise providing a third roll having a third rotationalaxis. The third rotational axis and the first rotational axis may bepositioned generally parallel to each other to form a second nip betweenthe first and third rolls. The method may comprise at least partiallyoverlapping the first substrate with the second substrate to form anarea of overlap between the first substrate and the second substrate inthe second nip, and aperturing the first substrate and the secondsubstrate in an area of overlap between the first and second substratesin the second nip. The method may comprise providing a plurality of weldanvils on the third roll, providing a welding unit proximate to thethird roll, and forming welds in the first and second substrates in thearea of overlap. The second substrate may be generally planar.

The welding unit may comprises an ultrasonic horn, wherein the welds areultrasonic welds. The welding unit may comprise a bonding roll, whereinthe welds are bonds.

The welding unit may be positioned downstream of the second nip.

The third roll may comprise a plurality of recesses defined in a radialouter surface of the third roll.

The method may comprise conveying the first substrate through the firstnip and the second nip, and conveying the second substrate through onlythe second nip.

The present disclosure is directed, in part, to a method of making athree-dimensional laminate on an absorbent article manufacturing line.The method may comprise conveying a first substrate in a machinedirection on the absorbent article manufacturing line, conveying asecond substrate in the machine direction on the absorbent articlemanufacturing line, providing a first roll having a first rotationalaxis, and providing a second roll having a second rotational axis. Thefirst rotational axis and the second rotational axis may be positionedgenerally parallel to each other to form a first nip between the firstand second rolls. The method may comprise creating in the first nip:three-dimensional elements in the first substrate, and apertures in thefirst substrate in portions free of the three-dimensional elements. Themethod may comprise providing a third roll having a third rotationalaxis. The third rotational axis and the first rotational axis may bepositioned generally parallel to each other to form a second nip betweenthe first and third rolls. The method may comprise applying adhesive tothe second substrate upstream of the second nip, at least partiallyoverlapping the first substrate with the second substrate in the secondnip to form an area of overlap between the first substrate and thesecond substrate, and aperturing the first substrate and the secondsubstrate in the area of overlap in the second nip.

A method of making a laminate, or a three-dimensional laminate, on anabsorbent article manufacturing line is provided. The method maycomprise conveying a first substrate in a machine direction on theabsorbent article manufacturing line, conveying a second substrate inthe machine direction on the absorbent article manufacturing line,providing a first roll having a first rotational axis, and providing asecond roll having a second rotational axis. The first rotational axisand the second rotational axis are positioned generally parallel to eachother to form a nip between the first and second rolls. The method maycomprise at least partially overlapping the first substrate with thesecond substrate on the second roll, or upstream of the second roll, toform an area of overlap between the first substrate and the secondsubstrate in the second nip, providing a plurality of weld anvils on thesecond roll, and providing a welding unit proximate to the second rolland configured to interact with at least some of the plurality of weldanvils. The method may comprise conveying the first and secondsubstrates on the second roll past the welding unit, forming weldsbetween the first and second substrates, and conveying the first andsecond substrates through the nip to form apertures and/orthree-dimensional elements in the laminate. The welding unit maycomprise an ultrasonic horn. The welds may comprise ultrasonic welds.Alternatively, the welding unit comprises a bonding roll (see e.g., FIG.36, roll 728). The welds comprise bonds. The three-dimensional elementsand/or the apertures may be formed in the first and second substrates inthe nip only in the area of overlap, or otherwise, between the first andsecond substrates.

In some instances, it may be desirable to first convey the first andsecond substrates 768 and 770 through the first and second rolls 708,710 and then convey the first and second substrates through the weldingunit and the roll 760 or through the roll 760 and an anvil roll.Registration of the bonds or welds may still be accomplished in asimilar fashion.

A method of making a laminate on an absorbent article manufacturing lineis provided. The method may comprise conveying a first substrate in amachine direction on the absorbent article manufacturing line, conveyinga second substrate in the machine direction on the absorbent articlemanufacturing line, and at least partially overlapping the firstsubstrate with the second substrate to form an area of overlap betweenthe first substrate and the second substrate. The method may compriseproviding a first roll having a first rotational axis. The first rollmay comprise a radial outer surface and protrusions extending from theradial outer surface. At least some of the protrusions may comprise weldanvils. Alternatively, the anvil welds may be positioned on the radialouter surface of the first roll and protrusions may not be provided. Themethod may comprise providing a welding unit proximate to the firstroll, conveying the first and second substrates intermediate the weldingunit and the first roll, and creating welds between the weld anvils andthe welding unit in the first and second substrates. The method maycomprise providing a second roll having a second rotational axis, andproviding a third roll having a third rotational axis. The third rollmay be positioned proximate to the second roll to form a nip between thesecond and third rolls. The second rotational axis may be positionedgenerally parallel to the third rotational axis. The method may compriseforming in the nip three-dimensional elements and/or apertures in thefirst and second substrates.

General Description of Absorbent Articles

The three-dimensional substrates, three-dimensional laminates, andlaminates discussed herein may be used as various components of theabsorbent articles described herein, such as topsheets,topsheet/acquisition layers, topsheet/secondary topsheet layers, and/orouter cover nonwoven materials, to name a few examples. Exampleabsorbent articles and their various components are discussed below.

An example absorbent article 910 according to the present disclosure,shown in the form of a taped diaper, is represented in FIGS. 39-40. FIG.39 is a plan view of the example absorbent article 910, garment-facingsurface 902 facing the viewer in a flat, laid-out state (i.e., noelastic contraction). FIG. 40 is a plan view of the example absorbentarticle 910 of FIG. 39, wearer-facing surface 904 facing the viewer in aflat, laid-out state. FIG. 41 is a front perspective view of theabsorbent article 910 of FIGS. 39 and 40 in a fastened configuration.The absorbent article 910 of FIGS. 39-41 is shown for illustrationpurposes only as the present disclosure may be used for making a widevariety of diapers, including adult incontinence products, pants, orother absorbent articles, such as sanitary napkins and absorbent pads,for example.

The absorbent article 910 may comprise a front waist region 912, acrotch region 914, and a back waist region 916. The crotch region 914may extend intermediate the front waist region 912 and the back waistregion 916. The front wait region 912, the crotch region 914, and theback waist region 916 may each be ⅓ of the length of the absorbentarticle 910. The absorbent article 910 may comprise a front end edge918, a back end edge 920 opposite to the front end edge 918, andlongitudinally extending, transversely opposed side edges 922 and 924defined by the chassis 952.

The absorbent article 910 may comprise a liquid permeable topsheet 926,a liquid impermeable backsheet 928, and an absorbent core 930 positionedat least partially intermediate the topsheet 926 and the backsheet 928.The absorbent article 910 may also comprise one or more pairs of barrierleg cuffs 932 with or without elastics 933, one or more pairs of legelastics 934, one or more elastic waistbands 936, and/or one or moreacquisition materials 938. The acquisition material or materials 938 maybe positioned intermediate the topsheet 926 and the absorbent core 930.An outer cover material 940, such as a nonwoven material, may cover agarment-facing side of the backsheet 928. The absorbent article 910 maycomprise back ears 942 in the back waist region 916. The back ears 942may comprise fasteners 946 and may extend from the back waist region 916of the absorbent article 910 and attach (using the fasteners 946) to thelanding zone area or landing zone material 944 on a garment-facingportion of the front waist region 912 of the absorbent article 910. Theabsorbent article 910 may also have front ears 947 in the front waistregion 912. The absorbent article 910 may have a central lateral (ortransverse) axis 948 and a central longitudinal axis 950. The centrallateral axis 948 extends perpendicular to the central longitudinal axis950.

In other instances, the absorbent article may be in the form of a panthaving permanent or refastenable side seams. Suitable refastenable seamsare disclosed in U.S. Pat. Appl. Pub. No. 2014/0005020 and U.S. Pat. No.9,421,137. Referring to FIGS. 42-46, an example absorbent article 910 inthe form of a pant is illustrated. FIG. 42 is a front perspective viewof the absorbent article 910. FIG. 43 is a rear perspective view of theabsorbent article 910. FIG. 44 is a plan view of the absorbent article910, laid flat, with the garment-facing surface facing the viewer.Elements of FIG. 42-46 having the same reference number as describedabove with respect to FIGS. 39-41 may be the same element (e.g.,absorbent core 930). FIG. 45 is an example cross-sectional view of theabsorbent article taken about line 45-45 of FIG. 44. FIG. 46 is anexample cross-sectional view of the absorbent article taken about line46-46 of FIG. 44. FIGS. 45 and 46 illustrate example forms of front andback belts 954, 956. The absorbent article 910 may have a front waistregion 912, a crotch region 914, and a back waist region 916. Each ofthe regions 912, 914, and 916 may be ⅓ of the length of the absorbentarticle 910. The absorbent article 910 may have a chassis 952 (sometimesreferred to as a central chassis or central panel) comprising a topsheet926, a backsheet 928, and an absorbent core 930 disposed at leastpartially intermediate the topsheet 926 and the backsheet 928, and anoptional acquisition material 938, similar to that as described abovewith respect to FIGS. 39-41. The absorbent article 910 may comprise afront belt 954 in the front waist region 912 and a back belt 956 in theback waist region 916. The chassis 952 may be joined to a wearer-facingsurface 904 of the front and back belts 954, 956 or to a garment-facingsurface 902 of the belts 954, 956. Side edges 923 and 925 of the frontbelt 954 may be joined to side edges 927 and 929, respectively, of theback belt 956 to form two side seams 958. The side seams 958 may be anysuitable seams known to those of skill in the art, such as butt seams oroverlap seams, for example. When the side seams 958 are permanentlyformed or refastenably closed, the absorbent article 910 in the form ofa pant has two leg openings 960 and a waist opening circumference 962.The side seams 958 may be permanently joined using adhesives or bonds,for example, or may be refastenably closed using hook and loopfasteners, for example.

Belts

Referring to FIGS. 45 and 46, the front and back belts 954 and 956 maycomprise front and back inner belt layers 966 and 967 and front and backouter belt layers 964 and 965 having an elastomeric material (e.g.,strands 968 or a film (which may be apertured)) disposed at leastpartially therebetween. The elastic elements 968 or the film may berelaxed (including being cut) to reduce elastic strain over theabsorbent core 930 or, may alternatively, run continuously across theabsorbent core 930. The elastics elements 968 may have uniform orvariable spacing therebetween in any portion of the belts. The elasticelements 968 may also be pre-strained the same amount or differentamounts. The front and/or back belts 954 and 956 may have one or moreelastic element free zones 970 where the chassis 952 overlaps the belts954, 956. In other instances, at least some of the elastic elements 968may extend continuously across the chassis 952.

The front and back inner belt layers 966, 967 and the front and backouter belt layers 964, 965 may be joined using adhesives, heat bonds,pressure bonds or thermoplastic bonds. Various suitable belt layerconfigurations can be found in U.S. Pat. Appl. Pub. No. 2013/0211363.

Front and back belt end edges 955 and 957 may extend longitudinallybeyond the front and back chassis end edges 919 and 921 (as shown inFIG. 44) or they may be co-terminus. The front and back belt side edges923, 925, 927, and 929 may extend laterally beyond the chassis sideedges 922 and 924. The front and back belts 954 and 956 may becontinuous (i.e., having at least one layer that is continuous) frombelt side edge to belt side edge (e.g., the transverse distances from923 to 925 and from 927 to 929). Alternatively, the front and back belts954 and 956 may be discontinuous from belt side edge to belt side edge(e.g., the transverse distances from 923 to 925 and 927 to 929), suchthat they are discrete.

As disclosed in U.S. Pat. No. 7,901,393, the longitudinal length (alongthe central longitudinal axis 950) of the back belt 956 may be greaterthan the longitudinal length of the front belt 954, and this may beparticularly useful for increased buttocks coverage when the back belt956 has a greater longitudinal length versus the front belt 954 adjacentto or immediately adjacent to the side seams 958.

The front outer belt layer 964 and the back outer belt layer 965 may beseparated from each other, such that the layers are discrete or,alternatively, these layers may be continuous, such that a layer runscontinuously from the front belt end edge 955 to the back belt end edge957. This may also be true for the front and back inner belt layers 966and 967—that is, they may also be longitudinally discrete or continuous.Further, the front and back outer belt layers 964 and 965 may belongitudinally continuous while the front and back inner belt layers 966and 967 are longitudinally discrete, such that a gap is formed betweenthem—a gap between the front and back inner and outer belt layers 964,965, 966, and 967 is shown in FIG. 45 and a gap between the front andback inner belt layers 966 and 967 is shown in FIG. 46.

The front and back belts 954 and 956 may include slits, holes, and/orperforations providing increased breathability, softness, and agarment-like texture. Underwear-like appearance can be enhanced bysubstantially aligning the waist and leg edges at the side seams 958(see FIGS. 42 and 43).

The front and back belts 954 and 956 may comprise graphics (see e.g.,978 of FIG. 39). The graphics may extend substantially around the entirecircumference of the absorbent article 910 and may be disposed acrossside seams 958 and/or across proximal front and back belt seams 915 and917; or, alternatively, adjacent to the seams 958, 915, and 917 in themanner described in U.S. Pat. No. 9,498,389 to create a moreunderwear-like article. The graphics may also be discontinuous.

Alternatively, instead of attaching belts 954 and 956 to the chassis 952to form a pant, discrete side panels may be attached to side edges ofthe chassis 922 and 924. Suitable forms of pants comprising discreteside panels are disclosed in U.S. Pat. Nos. 6,645,190; 8,747,379;8,372,052; 8,361,048; 6,761,711; 6,817,994; 8,007,485; 7,862,550;6,969,377; 7,497,851; 6,849,067; 6,893,426; 6,953,452; 6,840,928;8,579,876; 7,682,349; 7,156,833; and 7,201,744.

Topsheet

The topsheet 926 is the part of the absorbent article 910 that is incontact with the wearer's skin. The topsheet 926 may be joined toportions of the backsheet 928, the absorbent core 930, the barrier legcuffs 932, and/or any other layers as is known to those of ordinaryskill in the art. The topsheet 926 may be compliant, soft-feeling, andnon-irritating to the wearer's skin. Further, at least a portion of, orall of, the topsheet may be liquid permeable, permitting liquid bodilyexudates to readily penetrate through its thickness. A suitable topsheetmay be manufactured from a wide range of materials, such as porousfoams, reticulated foams, apertured plastic films, woven materials,nonwoven materials, woven or nonwoven materials of natural fibers (e.g.,wood or cotton fibers), synthetic fibers or filaments (e.g., polyesteror polypropylene or bicomponent PE/PP fibers or mixtures thereof), or acombination of natural and synthetic fibers. The topsheet may have oneor more layers. The topsheet may be apertured (FIG. 40, element 927),may have any suitable three-dimensional elements, and/or may have aplurality of embossments (e.g., a bond pattern). The topsheet may beapertured by overbonding a material and then rupturing the overbondsthrough ring rolling, such as disclosed in U.S. Pat. No. 5,628,097, toBenson et al., issued on May 13, 1997 and disclosed in U.S. Pat. Appl.Publication No. US 2016/0136014 to Arora et al. Any portion of thetopsheet may be coated with a skin care composition, an antibacterialagent, a surfactant, and/or other beneficial agents. The topsheet may behydrophilic or hydrophobic or may have hydrophilic and/or hydrophobicportions or layers. If the topsheet is hydrophobic, typically apertureswill be present so that bodily exudates may pass through the topsheet.The topsheets may comprise the laminates and/or three-dimensionalsubstrates described herein.

Backsheet

The backsheet 928 is generally that portion of the absorbent article 910positioned proximate to the garment-facing surface of the absorbent core930. The backsheet 928 may be joined to portions of the topsheet 926,the outer cover material 940, the absorbent core 930, and/or any otherlayers of the absorbent article by any attachment methods known to thoseof skill in the art. The backsheet 928 prevents, or at least inhibits,the bodily exudates absorbed and contained in the absorbent core 910from soiling articles such as bedsheets, undergarments, and/or clothing.The backsheet is typically liquid impermeable, or at least substantiallyliquid impermeable. The backsheet may, for example, be or comprise athin plastic film, such as a thermoplastic film having a thickness ofabout 0.012 mm to about 0.051 mm. Other suitable backsheet materials mayinclude breathable materials which permit vapors to escape from theabsorbent article, while still preventing, or at least inhibiting,bodily exudates from passing through the backsheet.

Outer Cover Material

The outer cover material (sometimes referred to as a backsheet nonwoven)940 may comprise one or more nonwoven materials joined to the backsheet928 and that covers the backsheet 928. The outer cover material 940forms at least a portion of the garment-facing surface 902 of theabsorbent article 910 and effectively “covers” the backsheet 928 so thatfilm is not present on the garment-facing surface 902. The outer covermaterial 940 may comprise a bond pattern, apertures, and/orthree-dimensional elements. The outer cover material may comprise thelaminates and/or three-dimensional substrates described above.

Absorbent Core

As used herein, the term “absorbent core” 930 refers to the component ofthe absorbent article 910 having the most absorbent capacity and thatcomprises an absorbent material. Referring to FIGS. 47-49, in someinstances, absorbent material 972 may be positioned within a core bag ora core wrap 974. The absorbent material may be profiled or not profiled,depending on the specific absorbent article. The absorbent core 930 maycomprise, consist essentially of, or consist of, a core wrap, absorbentmaterial 972, and glue enclosed within the core wrap. The absorbentmaterial may comprise superabsorbent polymers, a mixture ofsuperabsorbent polymers and air felt, only air felt, and/or a highinternal phase emulsion foam. In some instances, the absorbent materialmay comprise at least 80%, at least 85%, at least 90%, at least 95%, atleast 99%, or up to 100% superabsorbent polymers, by weight of theabsorbent material. In such instances, the absorbent material may freeof air felt, or at least mostly free of air felt. The absorbent coreperiphery, which may be the periphery of the core wrap, may define anysuitable shape, such as rectangular “T,” “Y,” “hour-glass,” or“dog-bone” shaped, for example. An absorbent core periphery having agenerally “dog bone” or “hour-glass” shape may taper along its widthtowards the crotch region 914 of the absorbent article 910.

Referring to FIGS. 47-49, the absorbent core 930 may have areas havinglittle or no absorbent material 972, where a wearer-facing surface ofthe core bag 974 may be joined to a garment-facing surface of the corebag 974. These areas having little or no absorbent material may bereferred to as “channels” 976. These channels can embody any suitableshapes and any suitable number of channels may be provided. In otherinstances, the absorbent core may be embossed to create the impressionof channels. The absorbent core in FIGS. 47-49 is merely an exampleabsorbent core. Many other absorbent cores with or without channels arealso within the scope of the present disclosure.

Barrier Leg Cuffs/Leg Elastics

Referring to FIGS. 39 and 40, for example, the absorbent article 910 maycomprise one or more pairs of barrier leg cuffs 932 and one or morepairs of leg elastics 934. The barrier leg cuffs 932 may be positionedlaterally inboard of leg elastics 934. Each barrier leg cuff 932 may beformed by a piece of material which is bonded to the absorbent article910 so it can extend upwards from a wearer-facing surface 4 of theabsorbent article 910 and provide improved containment of body exudatesapproximately at the junction of the torso and legs of the wearer. Thebarrier leg cuffs 932 are delimited by a proximal edge joined directlyor indirectly to the topsheet and/or the backsheet and a free terminaledge, which is intended to contact and form a seal with the wearer'sskin. The barrier leg cuffs 932 may extend at least partially betweenthe front end edge 918 and the back end edge 920 of the absorbentarticle 910 on opposite sides of the central longitudinal axis 950 andmay be at least present in the crotch region 914. The barrier leg cuffs932 may each comprise one or more elastics 933 (e.g., elastic strands orstrips) near or at the free terminal edge. These elastics 933 cause thebarrier leg cuffs 932 to help form a seal around the legs and torso of awearer. The leg elastics 934 extend at least partially between the frontend edge 918 and the back end edge 920. The leg elastics 934 essentiallycause portions of the absorbent article 910 proximate to the chassisside edges 922, 924 to help form a seal around the legs of the wearer.The leg elastics 934 may extend at least within the crotch region 914.

Elastic Waistband

Referring to FIGS. 39 and 40, the absorbent article 910 may comprise oneor more elastic waistbands 936. The elastic waistbands 936 may bepositioned on the garment-facing surface 902 or the wearer-facingsurface 904. As an example, a first elastic waistband 936 may be presentin the front waist region 912 near the front belt end edge 918 and asecond elastic waistband 936 may be present in the back waist region 916near the back end edge 920. The elastic waistbands 936 may aid insealing the absorbent article 910 around a waist of a wearer and atleast inhibiting bodily exudates from escaping the absorbent article 910through the waist opening circumference. In some instances, an elasticwaistband may fully surround the waist opening circumference of anabsorbent article.

Acquisition Materials

Referring to FIGS. 39, 40, 45, and 46, one or more acquisition materials938 may be present at least partially intermediate the topsheet 926 andthe absorbent core 930. The acquisition materials 938 are typicallyhydrophilic materials that provide significant wicking of bodilyexudates. These materials may dewater the topsheet 926 and quickly movebodily exudates into the absorbent core 930. The acquisition materials938 may comprise one or more nonwoven materials, foams, cellulosicmaterials, cross-linked cellulosic materials, air laid cellulosicnonwoven materials, spunlace materials, or combinations thereof, forexample. In some instances, portions of the acquisition materials 938may extend through portions of the topsheet 926, portions of thetopsheet 926 may extend through portions of the acquisition materials938, and/or the topsheet 926 may be nested with the acquisitionmaterials 938. Typically, an acquisition material 938 may have a widthand length that are smaller than the width and length of the topsheet926. The acquisition material may be a secondary topsheet in thefeminine pad context. The acquisition material may have one or morechannels as described above with reference to the absorbent core 930(including the embossed version). The channels in the acquisitionmaterial may align or not align with channels in the absorbent core 930.In an example, a first acquisition material may comprise a nonwovenmaterial and as second acquisition material may comprise a cross-linkedcellulosic material.

Landing Zone

Referring to FIGS. 39 and 40, the absorbent article 910 may have alanding zone area 944 that is formed in a portion of the garment-facingsurface 902 of the outer cover material 940. The landing zone area 944may be in the back waist region 916 if the absorbent article 10 fastensfrom front to back or may be in the front waist region 912 if theabsorbent article 910 fastens back to front. In some instances, thelanding zone 944 may be or may comprise one or more discrete nonwovenmaterials that are attached to a portion of the outer cover material 940in the front waist region 912 or the back waist region 916 dependingupon whether the absorbent article fastens in the front or the back. Inessence, the landing zone 944 is configured to receive the fasteners 946and may comprise, for example, a plurality of loops configured to beengaged with, a plurality of hooks on the fasteners 946, or vice versa.

Wetness Indicator/Graphics

Referring to FIG. 39, the absorbent articles 910 of the presentdisclosure may comprise graphics 978 and/or wetness indicators 980 thatare visible from the garment-facing surface 902. The graphics 978 may beprinted on the landing zone 940, the backsheet 928, and/or at otherlocations. The wetness indicators 980 are typically applied to theabsorbent core facing side of the backsheet 928, so that they can becontacted by bodily exudates within the absorbent core 930. In someinstances, the wetness indicators 980 may form portions of the graphics978. For example, a wetness indicator may appear or disappear andcreate/remove a character within some graphics. In other instances, thewetness indicators 980 may coordinate (e.g., same design, same pattern,same color) or not coordinate with the graphics 978.

Front and Back Ears

Referring to FIGS. 39 and 40, as referenced above, the absorbent article910 may have front and/or back ears 947, 942 in a taped diaper context.Only one set of ears may be required in most taped diapers. The singleset of ears may comprise fasteners 946 configured to engage the landingzone or landing zone area 944. If two sets of ears are provided, in mostinstances, only one set of the ears may have fasteners 946, with theother set being free of fasteners. The ears, or portions thereof, may beelastic or may have elastic panels. In an example, an elastic film orelastic strands may be positioned intermediate a first nonwoven materialand a second nonwoven material. The elastic film may or may not beapertured. The ears may be shaped. The ears may be integral (e.g.,extension of the outer cover material 940, the backsheet 928, and/or thetopsheet 926) or may be discrete components attached to a chassis 952 ofthe absorbent article on a wearer-facing surface 904, on thegarment-facing surface 902, or intermediate the two surfaces 904, 902.

Sensors

Referring again to FIG. 39, the absorbent articles of the presentdisclosure may comprise a sensor system 982 for monitoring changeswithin the absorbent article 910. The sensor system 982 may be discretefrom or integral with the absorbent article 910. The absorbent article910 may comprise sensors that can sense various aspects of the absorbentarticle 910 associated with insults of bodily exudates such as urineand/or BM (e.g., the sensor system 982 may sense variations intemperature, humidity, presence of ammonia or urea, various vaporcomponents of the exudates (urine and feces), changes in moisture vaportransmission through the absorbent articles garment-facing layer,changes in translucence of the garment-facing layer, and/or colorchanges through the garment-facing layer). Additionally, the sensorsystem 982 may sense components of urine, such as ammonia or urea and/orbyproducts resulting from reactions of these components with theabsorbent article 910. The sensor system 982 may sense byproducts thatare produced when urine mixes with other components of the absorbentarticle 910 (e.g., adhesives, agm). The components or byproducts beingsensed may be present as vapors that may pass through the garment-facinglayer. It may also be desirable to place reactants in the absorbentarticle that change state (e.g. color, temperature) or create ameasurable byproduct when mixed with urine or BM. The sensor system 982may also sense changes in pH, pressure, odor, the presence of gas,blood, a chemical marker or a biological marker or combinations thereof.The sensor system 982 may have a component on or proximate to theabsorbent article that transmits a signal to a receiver more distal fromthe absorbent article, such as an iPhone, for example. The receiver mayoutput a result to communicate to the caregiver a condition of theabsorbent article 910. In other instances, a receiver may not beprovided, but instead the condition of the absorbent article 910 may bevisually or audibly apparent from the sensor on the absorbent article.

Packages

The absorbent articles of the present disclosure may be placed intopackages. The packages may comprise polymeric films and/or othermaterials. Graphics and/or indicia relating to properties of theabsorbent articles may be formed on, printed on, positioned on, and/orplaced on outer portions of the packages. Each package may comprise aplurality of absorbent articles. The absorbent articles may be packedunder compression so as to reduce the size of the packages, while stillproviding an adequate amount of absorbent articles per package. Bypackaging the absorbent articles under compression, caregivers caneasily handle and store the packages, while also providing distributionsavings to manufacturers owing to the size of the packages.

Sanitary Napkin

Referring to FIG. 50, an absorbent article of the present disclosure maybe a sanitary napkin 1010. The sanitary napkin 1010 may comprise aliquid permeable topsheet 1014, a liquid impermeable, or substantiallyliquid impermeable, backsheet 1016, and an absorbent core 1018. Theliquid impermeable backsheet 1016 may or may not be vapor permeable. Theabsorbent core 1018 may have any or all of the features described hereinwith respect to the absorbent core 30 and, in some forms, may have asecondary topsheet 1019 (STS) instead of the acquisition materialsdisclosed above. The STS 1019 may comprise one or more channels, asdescribed above (including the embossed version). In some forms,channels in the STS 1019 may be aligned with channels in the absorbentcore 1018. The sanitary napkin 1010 may also comprise wings 1020extending outwardly with respect to a longitudinal axis 1080 of thesanitary napkin 1010. The sanitary napkin 1010 may also comprise alateral axis 1090. The wings 1020 may be joined to the topsheet 1014,the backsheet 1016, and/or the absorbent core 1018. The sanitary napkin1010 may also comprise a front edge 1022, a back edge 1024longitudinally opposing the front edge 1022, a first side edge 1026, anda second side edge 1028 longitudinally opposing the first side edge1026. The longitudinal axis 1080 may extend from a midpoint of the frontedge 1022 to a midpoint of the back edge 1024. The lateral axis 1090 mayextend from a midpoint of the first side edge 1028 to a midpoint of thesecond side edge 1028. The sanitary napkin 1010 may also be providedwith additional features commonly found in sanitary napkins as is knownin the art.

Examples Cross-Sections of Absorbent Articles

FIGS. 51-53 illustrate example cross-sectional views of absorbentarticles within the scope of the present disclosure. FIG. 51 is anexample cross-sectional view taken within a front waist region 912 of anabsorbent article. FIG. 52 is an example cross-sectional view takenwithin a crotch region 914 of an absorbent article. FIG. 53 is anexample cross-sectional view taken within a back waist region 916 of anabsorbent article. In FIGS. 51-53, an outer cover material is element940, a liquid permeable topsheet is element 926, opacity patches areelements 984, a liquid impermeable backsheet is element 928, anabsorbent core is element 930, with the core bag being element 974, anabsorbent material is element 972, and a distribution material iselement 986. The distribution material 986 may comprise cross-linkedcellulosic material and may be optional. An acquisition material iselement 988. A liquid permeable topsheet is element 926. Barrier legcuffs are elements 990. Elastics in the barrier leg cuffs are elements992. Back ears are elements 942. Fasteners on the back ears 942 areelements 946. Construction glues and/or bonds between the various layersand/or components have been removed for clarity. Other cross-sectionalconfigurations known to those of skill in the art are also within thescope of the present disclosure.

Absorbent Articles Comprising Laminates

The present disclosure is directed, in part, to an absorbent article.The absorbent article may comprise a lateral axis, a longitudinal axisextending perpendicular to the lateral axis, a liquid pervious,three-dimensional laminate, a liquid impervious backsheet, and anabsorbent core positioned at least partially intermediate thethree-dimensional laminate and the backsheet. The three-dimensionallaminate may comprise a first substrate having a first basis weight anda first lateral width, taken in a direction parallel to the lateralaxis, and a second substrate having a second basis weight and a secondlateral width, taken in the direction parallel to the lateral axis. Thefirst and second basis weights may be the same or different or the firstbasis weight may be greater than the second basis weight. The secondlateral width may be the same as, different than, or greater than thefirst lateral width. The first and second substrates may be at leastpartially overlapped to form an area of overlap between the firstsubstrate and the second substrate. The three-dimensional elements maybe formed only in the first substrate. The second substrate may begenerally planar. Apertures may be formed in the first and secondsubstrates. A plurality of welds may be formed in the first and secondsubstrates to join the first and second substrates. The first substratemay comprise compressed regions. The compressed regions may be formed inat least some of the three-dimensional elements or at least partiallyaround (or fully around) perimeters of at least some of the apertures.The three-dimensional elements may be formed in the first substrate onlyin the area of overlap. The apertures may be formed only in the area ofoverlap. An area outside of the area of overlap may be free of thethree-dimensional elements and/or the apertures. Alternatively, theapertures may be formed in the second substrate outside of the area ofoverlap.

The welds may comprise ultrasonic welds or bonds.

The three-dimensional laminate may form a portion of a topsheet of theabsorbent article. The first substrate may be hydrophobic and the secondsubstrate may be hydrophilic or may be less hydrophobic than the firstsubstrate or vice versa. In other instances, both of the substrates maybe hydrophobic or may be hydrophobic.

The first substrate may comprise a first material and the secondsubstrate may comprise a second material. The first and second materialsmay be the same or different.

The first substrate may or may not form a portion of a wearer-facingsurface of the absorbent article. The second substrate, or a portionthereof, may form a portion of a wearer-facing surface of the absorbentarticle.

A package comprising a plurality of the absorbent articles described inthis section may have an In-Bag Stack Height in the range of 70 mm to 90mm, according to the In-Bag Stack Height Test herein.

The present disclosure is directed, in part, to an absorbent article.The absorbent article may comprise a lateral axis, a longitudinal axisextending perpendicular to the lateral axis, a liquid pervious,three-dimensional laminate, a liquid impervious backsheet, and anabsorbent core positioned at least partially intermediate thethree-dimensional laminate and the backsheet. The three-dimensionallaminate may comprise a first substrate having a first basis weight anda first lateral width, taken in a direction parallel to the lateralaxis, and a second substrate having a second basis weight and a secondlateral width, taken in the direction parallel to the lateral axis. Thesecond lateral width may be greater than, the same as, or differentthan, the first lateral width. The first basis weight may be the same asor different than the second basis weight. The first and secondsubstrates may be at least partially overlapped to form an area ofoverlap between the first substrate and the second substrate. Thethree-dimensional laminate may comprise three-dimensional elementsformed in the first and second substrates in the area of overlap, aplurality of welds (e.g., ultrasonic welds or bonds) formed in the firstand second substrates in the area of overlap and joining the first andsecond substrates, and compressed regions formed in the first and secondsubstrates in the area of overlap. The three-dimensional laminate maycomprise apertures defined in the first and second substrates in thearea of overlap. The compressed regions may be formed in the portions ofat least some of the three-dimensional elements or at least partiallyaround (or fully around) perimeters of at least some of the apertures.Areas in the second substrate outside of the area of overlap may notcomprise the apertures or the three-dimensional elements.

The first substrate may be hydrophobic. The second substrate may behydrophilic or less hydrophobic than the first substrate. Alternatively,the first and second substrates may both be hydrophilic or may both behydrophobic.

The first substrate may comprise a first material and the secondsubstrate may comprise a second material. The first material and thesecond material may be the same or different in chemical composition,basis weight, fibers, and/or denier, for example. As an example, thefirst substrate may have a denier different than a denier of the secondmaterial.

Areas of the second substrate outside the area of overlap may begenerally planar or may have the three-dimensional elements and/or theapertures.

The first substrate may form a portion of, or all of, a wearer-facingsurface of the absorbent article. The second substrate may also form aportion of the wearer-facing surface of the absorbent article.Alternatively, the first substrate may not form the wearer-facingsurface.

Packages of Absorbent Articles

The absorbent articles of the present disclosure may be placed intopackages. The packages may comprise polymeric films and/or othermaterials. Graphics and/or indicia relating to properties of theabsorbent articles may be formed on, printed on, positioned on, and/orplaced on outer portions of the packages. Each package may comprise aplurality of absorbent articles. The absorbent articles may be packedunder compression so as to reduce the size of the packages, while stillproviding an adequate amount of absorbent articles per package. Bypackaging the absorbent articles under compression, caregivers caneasily handle and store the packages, while also providing distributionsavings to manufacturers owing to the size of the packages.

Accordingly, packages of the absorbent articles of the presentdisclosure may have an In-Bag Stack Height of less than about 110 mm,less than about 105 mm, less than about 100 mm, less than about 95 mm,less than about 90 mm, less than about 85 mm, less than about 80 mm,less than about 78 mm, less than about 76 mm, less than about 74 mm,less than about 72 mm, or less than about 70 mm, specifically recitingall 0.1 mm increments within the specified ranges and all ranges formedtherein or thereby, according to the In-Bag Stack Height Test describedherein. Alternatively, packages of the absorbent articles of the presentdisclosure may have an In-Bag Stack Height of from about 70 mm to about110 mm, from about 70 mm to about 105 mm, from about 70 mm to about 100mm, from about 70 mm to about 95 mm, from about 70 mm to about 90 mm,from about 70 mm to about 85 mm, from about 72 mm to about 80 mm, orfrom about 74 mm to about 78 mm, specifically reciting all 0.1 mmincrements within the specified ranges and all ranges formed therein orthereby, according to the In-Back Stack Height Test described herein.

FIG. 54 illustrates an example package 2000 comprising a plurality ofabsorbent articles 2004. The package 2000 defines an interior space 2002in which the plurality of absorbent articles 2004 are situated. Theplurality of absorbent articles 2004 are arranged in one or more stacks2006.

FIG. 55 is a top view of a portion of an example first roll 8 of thepair of rolls of FIG. 1. FIG. 55A is a cross-sectional view of a portionof the first roll 8 of the pair of rolls of FIG. 1 taken about line55A-55A of FIG. 55. The first roll 8 may comprise a first plurality ofprojections 20, a first plurality of recesses 22, and a first radialouter surface 16. The first plurality of projections 20 may eachcomprise a base 30 comprising side walls 34. At least some of, or mostof, the first plurality of projections 20 may each comprise first distalportions 24 comprising first distal ends 26 forming a point. The term“point” is defined herein. The first plurality of projections 20 mayeach comprise a central longitudinal axis 32. The first distal portions24 may comprise side walls 28. The side walls 28 may have a first angle,A, in a first portion proximate to the base 30 and a second angle, B, ina second portion distal from the base 30. Both the first and secondangles are relative to the central longitudinal axis 32. The firstangle, A, may be in the range of about 5 degrees to about 60 degrees,about 10 degrees to about 50 degrees, about 10 degrees to about 40degrees, about 10 degrees to about 35 degrees, about 10 degrees to about30 degrees, about 10 degrees to about 25 degrees, about 15 degrees toabout 21 degrees, or about 18 degrees, specifically reciting all 0.1degrees increments in the specified ranges and all ranges formed thereinor thereby. The second angle, B, may be in the range of about 15 degreesto about 70 degrees, about 15 degrees to about 50 degrees, about 15degrees to about 40 degrees, about 20 degrees to about 40 degrees, about25 degrees to about 35 degrees, about 27 degrees to about 29 degrees, orabout 28 degrees, specifically reciting all 0.1 degrees increments inthe specified ranges and all ranges formed therein or thereby.

FIG. 56 is a top view of a portion of an example second roll 10 of thepair of rolls of FIG. 1. FIG. 56A is a cross-sectional view of a portionof the second roll 10 taken about line 56A-56A of FIG. 56. The secondroll 10 may comprise a second plurality of projections 36, a secondplurality of recesses 38, and a second radial outer surface 18. Thesecond plurality of projections 36 may comprise a base 44 comprisingside walls. At least some of, or most of, the second plurality ofprojections 36 may each comprise second distal portions 40 comprisingsecond distal ends 42. The second distal ends may be flat orsubstantially flat, or may comprise arcuate portions or dome-likestructures. The second plurality of projections 36 may each comprise acentral longitudinal axis 48. The second distal portions 40 may compriseshoulders 46. The shoulders 46 may have a first angle, C, in a firstportion proximate to the base 44 and a second angle, D, in a secondportion distal from the base 44. Both the first and second angles arerelative to the central longitudinal axis 48. The first angle, C, may bein the range of about 2 degrees to about 50 degrees, about 2 degrees toabout 40 degrees, about 2 degrees to about 30 degrees, about 2 degreesto about 20 degrees, about 5 degrees to about 20 degrees, about 5degrees to about 15 degrees, about 8 degrees to about 12 degrees, orabout 10 degrees, specifically reciting all 0.1 degrees increments inthe specified ranges and all ranges formed therein or thereby. Thesecond angle, D, may be in the range of about 2 degrees to about 50degrees, about 2 degrees to about 40 degrees, about 2 degrees to about30 degrees, about 2 degrees to about 20 degrees, about 3 degrees toabout 20 degrees, about 3 degrees to about 15 degrees, about 5 degreesto about 10 degrees, or about 7 degrees, specifically reciting all 0.1degrees increments in the specified ranges and all ranges formed thereinor thereby.

Upon information and belief, it may be desirable, in some instances, tohave the first angle, A, and the first angle, C, to be different toallow for more concentrated (smaller) compressed regions formed in thesubstrates intermediate the shoulders 46 and the side walls 28 of thefirst distal portions 24. Stated another way, having the first angle, A,and the first angle, C, be different may cause the compressed regions toform ring-like structures compared to partial cone-like structures whenthe angles A and C are the same, or substantially the same (e.g., withina few degrees). If the first angle, A, and the first angle, C, are thesame or substantially the same, the compressed regions formed in thesubstrates may be larger, thereby potentially impacting softness of theformed substrates. Compressed regions having ring-like structures mayprovide improved softness of the formed substrates.

FIG. 57 is an example of a wrapping configuration for the substrate orsubstrates passing through the various first and second rolls 8, 10 ofthe present disclosure. The first roll 8 may rotate about the firstrotational axis 12 in the direction indicated by the arrow. The secondroll 10 may rotate about the second rotational axis 14 in the directionindicated by the arrow. The precursor substrate 4 is conveyed partiallyaround the first roll 8 before entering the nip 6. This allows theprecursor substrate 4 to be locked in place on the first roll 8 becauseof the first plurality of projections 20 and the first distal ends 26thereof piercing through the precursor substrate 4. The precursorsubstrate 4 is then conveyed through the nip 6 and then is conveyed atleast partially around the second roll 10 such that the formed substrate2 remains engaged with the second plurality of projections 36 on thesecond roll 10 to lock the three-dimensional structure into the formedsubstrate 2. This type of wrapping configuration may be known as an“S-wrap” configuration. As discussed herein, the first and second rolls8, 10 and/or the precursor substrate 4 may be heated to aid in formationof the substrate 2. Any of the first and second rolls described hereinmay use this wrapping configuration or use the example wrappingconfiguration of FIG. 58 or may be conveyed through the nip asillustrated as in example in FIG. 1, for example. Other wrappingconfigurations are also within the scope of the present disclosure.

FIG. 58 is another example of a wrapping configuration for the substrateor substrates passing through various the first and second rolls 8, 10of the present disclosure. The first roll 8 may rotate about the firstrotational axis 12 in the direction indicated by the arrow. The secondroll 10 may rotate about the second rotational axis 14 in the directionindicated by the arrow. The precursor substrate 4 is conveyed partiallyaround the first roll 8 before entering the nip 6. This allows theprecursor substrate 4 to be locked in place on the first roll 8 becauseof the first plurality of projections 20 and the first distal ends 26thereof piercing through the precursor substrate 4. The precursorsubstrate 4 is then conveyed through the nip 6 and then is conveyed atleast partially around the second roll 10 such that the formed substrate2 remains engaged with the second plurality of projections 36 on thesecond roll 10 to lock the three-dimensional structure into the formedsubstrate 2. As discussed herein, the first and second rolls 8, 10and/or the precursor substrate may be heated to aid in formation of thesubstrate 2.

Tests In-Bag Stack Height Test

The in-bag stack height of a package of absorbent articles is determinedas follows:

Equipment

A thickness tester with a flat, rigid horizontal sliding plate is used.The thickness tester is configured so that the horizontal sliding platemoves freely in a vertical direction with the horizontal sliding platealways maintained in a horizontal orientation directly above a flat,rigid horizontal base plate. The thickness tester includes a suitabledevice for measuring the gap between the horizontal sliding plate andthe horizontal base plate to within ±0.5 mm. The horizontal slidingplate and the horizontal base plate are larger than the surface of theabsorbent article package that contacts each plate, i.e. each plateextends past the contact surface of the absorbent article package in alldirections. The horizontal sliding plate exerts a downward force of850±1 gram-force (8.34 N) on the absorbent article package, which may beachieved by placing a suitable weight on the center of thenon-package-contacting top surface of the horizontal sliding plate sothat the total mass of the sliding plate plus added weight is 850±1grams.

Test Procedure

Absorbent article packages are equilibrated at 23±2° C. and 50±5%relative humidity prior to measurement.

The horizontal sliding plate is raised and an absorbent article packageis placed centrally under the horizontal sliding plate in such a waythat the absorbent articles within the package are in a horizontalorientation (see FIG. 54). Any handle or other packaging feature on thesurfaces of the package that would contact either of the plates isfolded flat against the surface of the package so as to minimize theirimpact on the measurement. The horizontal sliding plate is loweredslowly until it contacts the top surface of the package and thenreleased. The gap between the horizontal plates is measured to within±0.5 mm ten seconds after releasing the horizontal sliding plate. Fiveidentical packages (same size packages and same absorbent articlescounts) are measured and the arithmetic mean is reported as the packagewidth. The “In-Bag Stack Height”=(package width/absorbent article countper stack)×10 is calculated and reported to within ±0.5 mm.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany embodiment disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such embodiment. Further, to the extent that any meaningor definition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present disclosure have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications may be made withoutdeparting from the spirit and scope of the present disclosure. It istherefore intended to cover in the appended claims all such changes andmodifications that are within the scope of this disclosure.

What is claimed is:
 1. An absorbent article comprising: a lateral axis; a longitudinal axis extending perpendicular to the lateral axis; a liquid pervious, three-dimensional laminate; a liquid impervious backsheet; and an absorbent core positioned at least partially intermediate the three-dimensional laminate and the backsheet; wherein the three-dimensional laminate comprises: a first substrate having a first basis weight and a first lateral width, taken in a direction parallel to the lateral axis; a second substrate having a second basis weight and a second lateral width, taken in the direction parallel to the lateral axis, wherein the second lateral width is larger than the first lateral width, and wherein the first and second substrates are at least partially overlapped to form an area of overlap between the first substrate and the second substrate; three-dimensional elements formed only in the first substrate in the area of overlap; wherein the second substrate is generally planar; apertures defined in the first and second substrates in the area of overlap; and a plurality of welds formed in the first and second substrates in the area of overlap and joining the first and second substrates.
 2. The absorbent article of claim 1, wherein welds comprise ultrasonic welds.
 3. The absorbent article of claim 1, wherein the welds comprise bonds.
 4. The absorbent article of claim 1, wherein the three-dimensional laminate forms a portion of a topsheet of the absorbent article, wherein the first substrate is hydrophobic, and wherein the second substrate is hydrophilic or less hydrophobic than the first substrate.
 5. The absorbent article of claim 1, wherein the first substrate comprises a first material, wherein the second substrate comprises a second material, and wherein the first material is different than the second material.
 6. The absorbent article of claim 1, wherein areas of the second substrate outside of the area of overlap is free of apertures and/or three-dimensional elements.
 7. The absorbent article of claim 1, wherein the first basis weight is different than the second basis weight.
 8. The absorbent article of claim 1, wherein the three-dimensional laminate comprises compressed regions in the first substrate, and wherein the compressed regions are formed in at least some of the three-dimensional elements or at least partially around portions of perimeters of at least some of the apertures.
 9. The absorbent article of claim 1, wherein the first substrate forms a portion of a wearer-facing surface of the absorbent article.
 10. The absorbent article of claim 1, wherein the first substrate does not form a portion of a wearer-facing surface of the absorbent article.
 11. An absorbent article comprising: a lateral axis; a longitudinal axis extending perpendicular to the lateral axis; a liquid pervious, three-dimensional laminate; a liquid impervious backsheet; and an absorbent core positioned at least partially intermediate the three-dimensional laminate and the backsheet; wherein the three-dimensional laminate comprises: a first substrate having a first lateral width, taken in a direction parallel to the lateral axis; a second substrate having a second lateral width, taken in the direction parallel to the lateral axis, wherein the second lateral width is larger than the first lateral width, and wherein the first and second substrates are at least partially overlapped to form an area of overlap; three-dimensional elements formed in the first substrate; apertures defined in the first and second substrates and in portions of the first substrate free of the three-dimensional elements; wherein the second substrate is generally planar; and a plurality of ultrasonic welds formed first and second substrates in the area of overlap and joining the first and second substrates.
 12. The absorbent article of claim 11, wherein the first substrate forms a portion of a wearer-facing surface of the absorbent article.
 13. The absorbent article of claim 11, wherein the first substrate does not form a portion of a wearer-facing surface of the absorbent article.
 14. The absorbent article of claim 11, wherein areas in the second substrate outside of the area of overlap are free of the apertures.
 15. The absorbent article of claim 11, wherein areas in the second substrate outside of the area of overlap are free of the three-dimensional elements.
 16. The absorbent article of claim 11, wherein the first substrate comprises compressed regions in the first substrate, and wherein the compressed regions are formed in at least some of the three-dimensional elements or at least partially around at least some of the apertures.
 17. An absorbent article comprising: a liquid pervious, three-dimensional laminate; a liquid impervious backsheet; and an absorbent core positioned at least partially intermediate the three-dimensional laminate and the backsheet; wherein the three-dimensional laminate comprises: a first substrate having a first basis weight and a first lateral width, taken in a direction parallel to the lateral axis; a second substrate having a second, basis weight and a second lateral width, taken in the direction parallel to the lateral axis, wherein the second lateral width is different than the first lateral width, and wherein the first and second substrates are overlapped to form an area of overlap; three-dimensional elements formed in the first substrate; apertures defined in the first and second substrates and in portions free of the three-dimensional elements; welds formed in the first and second substrates in the area of overlap and joining the first and second substrates; wherein the second substrate is generally planar; and compressed regions formed in the first substrate.
 18. The absorbent article of claim 17, wherein the welds comprise ultrasonic welds.
 19. The absorbent article of claim 17, wherein the welds comprise bonds.
 20. The absorbent article of claim 17, wherein the compressed regions are formed in the first substrate in the area of overlap, and wherein the compressed regions are formed in at least some of the three-dimensional elements or at least partially around at least some of the apertures. 